Generac Power Systems Portable Generator 004916 0 User Manual
Installation and  
Owner’s Manual  
Air-cooled, Prepackaged  
Automatic Standby Generators  
Model No. 004916-0  
(10 kW NG, 11 kW LP)  
*This manual should  
remain with the unit.  
Not intended for use as Primary Power in place of utility or in  
life-support applications.  
DANGER  
DEADLY EXHAUST FUMES. OUTDOOR INSTALLATION ONLY!  
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Table of Contents  
Air-cooled 11 kW Generators  
Introduction ............................... Inside Front Cover  
Read This Manual Thoroughly................................. IFC  
Contents .................................................................. IFC  
Operation and Maintenance..................................... IFC  
How to Obtain Service ............................................. IFC  
Authorized Dealer Locator Number.............................IFC  
Section 3 – Operation ...........................................11  
3.1 Break-in Procedure .............................................11  
3.2 Using the AUTO/OFF/MANUAL Switch ................11  
3.2.1 “Auto” Position ........................................11  
3.2.2 “Off” Position ..........................................12  
3.2.3 “Manual” Position....................................12  
3.3 Automatic Transfer Operation.............................12  
3.4 Sequence of Automatic Operation .......................12  
3.5 Setting the Exercise Timer ..................................13  
3.6 Protection Systems..............................................13  
3.6.1 Low Oil Pressure Switch.........................13  
3.6.2 High Temperature Switch........................13  
3.6.3 Overcrank...............................................13  
3.6.4 Overspeed...............................................13  
3.6.5 Low Battery.............................................14  
Safety Rules ............................................................... 2  
Standards Index..................................................3  
Section 1 – General Information.......................... 4  
1.1 Unpacking/Inspection............................................4  
1.2 Protection Systems................................................4  
1.3 System Set LED ....................................................4  
1.4 Accessory Features................................................4  
1.4.1 12 Volt DC Outlet......................................4  
1.4.2 120 Volt AC Outlet ....................................5  
1.5 The Generator.......................................................5  
1.6 Specifications........................................................6  
1.6.1 Generator..................................................6  
1.6.2 Engine.......................................................6  
1.7 Fuel Requirements and Recommendations ...........7  
1.8 Fuel Consumption.................................................7  
1.9 Reconfiguring the Fuel System ..............................7  
1.10 Location ................................................................7  
1.10.1 Generator..................................................7  
1.10.2 Transfer Switch ........................................8  
1.11 Battery Installation................................................8  
1.12 The Battery ...........................................................8  
Section 4 – Maintenance......................................14  
4.1 System Fuse ........................................................14  
4.1.1 7.5 Amp Fuse..........................................14  
4.2 Checking the Engine Oil Level.............................14  
4.3 Changing the Engine Oil......................................14  
4.3.1 Engine Oil Recommendations.................14  
4.3.2 Oil Change Procedure .............................15  
4.4 Changing the Oil Filter ........................................15  
4.5 Changing the Engine Air Cleaner.........................15  
4.6 Spark Plugs.........................................................15  
4.7 Battery Maintenance............................................16  
4.8 Adjusting GT-990 Valve Clearance .......................16  
4.9 Cooling System....................................................17  
4.10 Attention After Submersion.................................17  
4.11 Corrosion Protection...........................................17  
4.12 Out of Service Procedure.....................................17  
4.12.1 Removal From Service ............................17  
4.12.2 Return to Service ....................................18  
4.13 Service Schedule.................................................19  
Section 2 – Post Installation Start-up  
and Adjustments ................................ 9  
2.1 Before Initial Startup.............................................9  
2.2 Check Transfer Switch Operation .........................9  
2.3 Electrical Checks...................................................9  
2.4 Generator Tests Under Load...............................10  
2.5 Checking Automatic Operation............................10  
2.6 Voltage Regulator Adjustment..............................11  
Section 5 – Troubleshooting................................20  
5.1 Troubleshooting Guide........................................20  
Section 6 – Installation Diagram........................21  
Section 7 – Electrical Data...................................22  
Section 8 – Exploded Views and  
Parts Lists...........................................26  
Section 9 – Notes ...................................................38  
Section 10 – Warranty...........................................40  
1
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IMPORTANT SAFETY INSTRUCTIONS  
Air-cooled 11 kW Generators  
SAVE THESE INSTRUCTIONS – The manufacturer suggests that these rules for safe  
operation be copied and posted near the unit’s installation site. Safety should be stressed to  
all operators and potential operators of this equipment.  
WARNING:  
contains chemicals known to the state  
of California to cause cancer, birth  
defects or other reproductive harm.  
GENERAL HAZARDS  
The engine exhaust from this product  
• For safety reasons, the manufacturer recommends  
that the installation, initial start-up and main-  
tenance of this equipment is carried out by an  
Authorized Dealer.  
• The engine exhaust fumes contain carbon monox-  
ide, which can be DEADLY. This dangerous gas, if  
breathed in sufficient concentrations, can cause  
unconsciousness or even death. This exhaust  
system must be installed properly, in strict com-  
pliance with applicable codes and standards.  
Following installation, do nothing that might ren-  
der the system unsafe or in noncompliance with  
such codes and standards.  
• Keep hands, feet, clothing, etc., away from drive  
belts, fans, and other moving or hot parts. Never  
remove any drive belt or fan guard while the unit  
is operating.  
WARNING:  
This product contains or emits chemicals  
known to the state of California to cause  
cancer, birth defects or other reproductive harm.  
Study these SAFETY RULES carefully before install-  
ing, operating or servicing this equipment. Become  
familiar with this Owner’s Manual and with the  
unit. The generator can operate safely, efficiently and  
reliably only if it is properly installed, operated and  
maintained. Many accidents are caused by failing to  
follow simple and fundamental rules or precautions.  
The manufacturer cannot anticipate every possible  
circumstance that might involve a hazard. The warn-  
ings in this manual, and on tags and decals affixed  
to the unit are, therefore, not all-inclusive. If using  
a procedure, work method or operating technique  
the manufacturer does not specifically recommend,  
ensure that it is safe for others. Also make sure the  
procedure, work method or operating technique uti-  
lized does not render the generator unsafe.  
• Adequate, unobstructed flow of cooling and venti-  
lating air is critical to correct generator operation.  
Do not alter the installation or permit even partial  
blockage of ventilation provisions, as this can seri-  
ously affect safe operation of the generator. The  
generator MUST be installed outdoors.  
• When working on this equipment, remain alert  
at all times. Never work on the equipment when  
physically or mentally fatigued.  
• Inspect the generator regularly, and contact the  
nearest Authorized Dealer for parts needing repair  
or replacement.  
• Before performing any maintenance on the gen-  
erator, disconnect its battery cables to prevent  
accidental start up. Disconnect the cable from the  
battery post indicated by a NEGATIVE, NEG or (–)  
first. Reconnect that cable last.  
DANGER  
Despite the safe design of this generator,  
operating this equipment imprudently, neglecting  
its maintenance or being careless can cause  
possible injury or death. Permit only responsible  
and capable persons to operate or maintain this  
equipment.  
• Never use the generator or any of its parts as a  
step. Stepping on the unit can stress and break  
parts, and may result in dangerous operating con-  
ditions from leaking exhaust gases, fuel leakage,  
oil leakage, etc.  
Potentially lethal voltages are generated by  
these machines. Ensure all steps are taken to  
render the machine safe before attempting to  
work on the generator.  
Parts of the generator are rotating and/or hot  
during operation. Exercise care near running  
generators.  
2
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IMPORTANT SAFETY INSTRUCTIONS  
Air-cooled 11 kW Generators  
• Keep a fire extinguisher near the generator at all  
times. Extinguishers rated “ABC” by the National  
Fire Protection Association are appropriate for  
use on the standby electric system. Keep the extin-  
guisher properly charged and be familiar with its  
use. Consult the local fire department with any  
questions pertaining to fire extinguishers.  
ELECTRICAL HAZARDS  
• All generators covered by this manual produce  
dangerous electrical voltages and can cause fatal  
electrical shock. Utility power delivers extremely  
high and dangerous voltages to the transfer switch  
as does the standby generator when it is in opera-  
tion. Avoid contact with bare wires, terminals,  
connections, etc., while the unit is running. Ensure  
all appropriate covers, guards and barriers are in  
place before operating the generator. If work must  
be done around an operating unit, stand on an  
insulated, dry surface to reduce shock hazard.  
• Do not handle any kind of electrical device while  
standing in water, while barefoot, or while hands or  
feet are wet. DANGEROUS ELECTRICAL SHOCK  
MAY RESULT.  
• The National Electrical Code (NEC) requires the  
frame and external electrically conductive parts of  
the generator to be connected to an approved earth  
ground. Local electrical codes also may require  
proper grounding of the generator electrical sys-  
tem.  
• After installing this home standby electrical sys-  
tem, the generator may crank and start at any time  
without warning. When this occurs, load circuits  
are transferred to the STANDBY (GENERATOR)  
power source. To prevent possible injury if such a  
start and transfer occur, always set the generator’s  
AUTO/OFF/MANUAL switch to its OFF position  
before working on equipment and remove the 7.5A  
and 15A fuses from the generator control panel.  
• In case of accident caused by electric shock, imme-  
diately shut down the source of electrical power. If  
this is not possible, attempt to free the victim from  
the live conductor. AVOID DIRECT CONTACT WITH  
THE VICTIM. Use a nonconducting implement,  
such as a dry rope or board, to free the victim from  
the live conductor. If the victim is unconscious,  
apply first aid and get immediate medical help.  
• Never wear jewelry when working on this equip-  
ment. Jewelry can conduct electricity resulting in  
electric shock, or may get caught in moving com-  
ponents causing injury.  
EXPLOSION HAZARDS  
• Do not smoke around the generator. Wipe up any  
fuel or oil spills immediately. Ensure that no com-  
bustible materials are left in the generator com-  
partment, or on or near the generator, as FIRE or  
EXPLOSION may result. Keep the area surround-  
ing the generator clean and free from debris.  
• Gaseous fluids such as natural gas and liquid pro-  
pane (LP) gas are extremely EXPLOSIVE. Install  
the fuel supply system according to applicable  
fuel-gas codes. Before placing the home standby  
electric system into service, fuel system lines must  
be properly purged and leak tested according to  
applicable code. After installation, inspect the fuel  
system periodically for leaks. No leakage is permit-  
ted.  
‹
STANDARDS INDEX  
In the absence of pertinent standards, codes, regu-  
lations and laws, the published information listed  
below may be used as installation guide for this  
equipment.  
1. NFPA No. 37, STATIONARY COMBUSTION  
ENGINES AND GAS TURBINES, available from  
the National Fire Protection Association, 470  
Atlantic Avenue, Boston, MA 02210.  
2. NFPA No. 76A, ESSENTIAL ELECTRICAL  
SYSTEMS FOR HEALTH CARE FACILITIES,  
available same as Item 1.  
3. NFPA No. 54, NATIONAL FUEL GAS CODE,  
available same as Item 1.  
4. NFPA No. 58, AMERICAN NATIONAL STANDARD  
FOR STORAGE AND HANDLING OF LIQUEFIED  
PETROLEUM GAS, available same as Item 1.  
5. NFPA No. 70, NFPA HANDBOOK OF NATIONAL  
ELECTRIC CODE, available same as Item 1.  
6. Article X, NATIONAL BUILDING CODE, available  
from the American Insurance Association, 85  
John Street, New York, N.Y. 10038.  
FIRE HAZARDS  
• For fire safety, the generator must be installed  
and maintained properly. Installation always must  
comply with applicable codes, standards, laws  
and regulations. Adhere strictly to local, state and  
national electrical and building codes. Comply with  
regulations the Occupational Safety and Health  
Administration (OSHA) has established. Also,  
ensure that the generator is installed in accordance  
with the manufacturer’s instructions and rec-  
ommendations. Following proper installation, do  
nothing that might alter a safe installation and ren-  
der the unit in noncompliance with the aforemen-  
tioned codes, standards, laws and regulations.  
7. AGRICULTURAL WIRING HANDBOOK, avail-  
able from the Food and Energy Council, 909  
University Avenue, Columbia, MO 65201.  
8. ASAE  
EP-3634,  
INSTALLATION  
AND  
MAINTENANCEOFFARMSTANDBYELECTRICAL  
SYSTEMS, available from the American Society  
of Agricultural Engineers, 2950 Niles Road, St.  
Joseph, MI 49085.  
9. NFPA No. 30, FLAMMABLE AND COMBUSTIBLE  
LIQUIDS CODE, available same as Item 1.  
3
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Section 1 — General Information  
Air-cooled 11 kW Generators  
1.3 SYSTEM SET LED  
DANGER  
The “System Set” LED is lit when all of the following  
conditions are true:  
Only qualified electricians or contractors should  
attempt such installations, which must comply  
strictly with applicable codes, standards and  
regulations.  
1. The AUTO/OFF/MANUAL switch is set to the  
AUTO position.  
2. The utility voltage being supplied to the unit is  
being sensed by the PCB. If the utility sense volt-  
age is not connected to the unit or if it is below  
168 volts AC, then the system set light will flash  
rapidly. This indicates that if the AUTO/OFF/  
MANUAL switch is placed in the Auto position ,  
the generator will start.  
1.1 UNPACKING/INSPECTION  
After unpacking, carefully inspect the contents  
for damage.  
• This standby generator set has been factory sup-  
plied with a weather protective enclosure that is  
intended for outdoor installation only.  
3. The “Not In Auto” dip switch is set to the OFF  
position on the control board.  
4. No alarms are present, for example, low oil pres-  
sure, high temperature, etc.  
If this generator is used to power electrical load  
circuits normally powered by a utility power  
1.4 ACCESSORY FEATURES  
source, it is required by code to install a transfer  
switch. The transfer switch must effectively iso-  
late the electrical system from the utility distri-  
bution system when the generator is operating  
(NEC 700, 701 & 702). Failure to isolate an electri-  
cal system by such means will result in damage  
to the generator and also may result in injury or  
death to utility power workers due to backfeed  
of electrical energy.  
‹
1.4.1 12 VOLT DC OUTLET  
The generator is equipped with a 12 volt DC accesso-  
ry outlet located in the system control panel (Figure  
1.1). With the generator running or in standby mode,  
this outlet may be used to temporarily power low  
power accessories such as an inspection light, cell  
phone, radio or other automotive style accessory with  
a 7.5 amp maximum current draw.  
If any loss or damage is noted at time of delivery, have  
the person(s) making the delivery note all damage  
on the freight bill or affix their signature under the  
consignor's memo of loss or damage.  
Figure 1.1 — 12 Volt DC Outlet  
If a loss or damage is noted after delivery, separate  
the damaged materials and contact the carrier for  
claim procedures.  
“Concealed damage” is understood to mean damage  
to the contents of a package that is not in evidence at  
the time of delivery, but is discovered later.  
1.2 PROTECTION SYSTEMS  
Unlike an automobile engine, the generator may have  
to run for long periods of time with no operator pres-  
ent to monitor engine conditions. For that reason, the  
engine is equipped with the following systems that  
protect it against potentially damaging conditions:  
1. Low Oil Pressure Sensor  
2. High Temperature Sensor  
3. Overcrank  
4. Overspeed  
5. Low Battery  
There are LED readouts on the control panel to notify  
the user that one of these faults has occurred. There  
is also a “System Set” LED that is lit when all of the  
conditions describe in Section 1.3 are true.  
The 12 volt DC accessory socket is not intended  
for continuous use. Power for this socket is  
drawn from the engine battery. Extended use  
will drain the battery and the engine may not  
start. Power available at this socket is limited to  
7.5 amps maximum.  
4
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Section 1 — General Information  
Air-cooled 11 kW Generators  
Figure 1.2 — 120 Volt AC Outlet  
‹
1.4.2 120 VOLT AC OUTLET  
The generator is equipped with an external, 15 amp,  
120 volt, GFCI convenience outlet located on the  
front of the unit (Figure 1.2). When the generator is  
running, in the absence of utility power, this outlet  
may be used to power items outside the home such  
as lights or power tools. This outlet may also be used  
when utility power is present by running the genera-  
tor in manual mode.  
120 VAC  
GFCI OUTLET  
A dedicated push-pull style circuit breaker is located  
on the control panel for this outlet. Pull the breaker  
stem out to open the breaker; push in to reset or  
close the breaker.  
Front View  
1.5 THE GENERATOR  
Figure 1.3 – 11 kW, V-twin GT-990 Engine  
Overhead View  
Exhaust  
Enclosure  
Data Decal  
Control Panel  
GFCI Outlet  
Right Side View  
Air Filter  
Oil Dipstick  
Oil Filter  
Battery Compartment  
Fuel Regulator  
5
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Section 1 — General Information  
Air-cooled 11 kW Generators  
1.6 SPECIFICATIONS  
‹
1.6.1 GENERATOR  
Model 04916-0  
10,000 NG/11,000 LP  
120/240  
Rated Max. Continuous Power Capacity (Watts*)  
Rated Voltage  
Rated Max. Continuous Load Current (Amps)  
120 Volts**  
83.3 NG/91.7 LP  
240 Volts  
41.7 NG/45.8 LP  
Main Line Circuit Breaker  
Phase  
45 Amp  
1
Number of Rotor Poles  
Rated AC Frequency  
Power Factor  
2
60 Hz  
1
Recommended Air Filter  
Part # C8127  
Battery Requirement  
at -17.8° C (0° F)  
Group 26/26R 12 Volts and  
525 Cold-cranking Amperes Minimum  
Weight  
495 Pounds  
Output Sound Level @ 23 ft (7m) at full load  
Normal Operating Range  
62.2 db (A)  
-20°F (-28.8°C) to 104°F (40°C)  
* Maximum wattage and current are subject to and limited by such factors as fuel Btu content, ambient temperature, altitude, engine power and condition, etc. Maximum power  
decreases about 3.5 percent for each 1,000 feet above sea level; and also will decrease about 1 percent for each 6° C (10° F) above 16° C (60° F) ambient temperature.  
** Load current values shown for 120 volts are maximum TOTAL values for two separate circuits. The maximum current in each circuit must not exceed the value stated for 240  
volts.  
‹
1.6.2 ENGINE  
Model 04916-0  
GT-990  
Type of Engine  
Number of Cylinders  
Rated Horsepower  
Displacement  
2
30 @ 3,600 rpm  
992cc  
Cylinder Block  
Valve Arrangement  
Ignition System  
Recommended Spark Plug  
Spark Plug Gap  
Compression Ratio  
Starter  
Aluminum w/Cast Iron Sleeve  
Overhead Valves  
Solid-state w/Magneto  
RC14YC  
0.76 mm (0.030 inch)  
9.5:1  
12Vdc  
Oil Capacity Including Filter  
Recommended Oil Filter  
Recommended Air Filter  
Operating RPM  
Approx. 1.7 Qts  
Part # 70185  
Part # 0C8127  
2,700  
6
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Section 1 — General Information  
Air-cooled 11 kW Generators  
3. Remove the pipe plug from the LP (left) outlet  
1.7 FUEL REQUIREMENTS  
port.  
AND RECOMMENDATIONS  
4. Install the brass hose fitting in the LP (left) outlet  
With LP gas, use only the vapor withdrawal sys-  
tem. This type of system uses the vapors formed  
above the liquid fuel in the storage tank.  
port.  
5. Install the pipe plug in the NG (right) outlet  
port.  
6. Connect the carburetor fuel hose to the LP (left)  
outlet port of the demand regulator.  
7. Reverse the procedure to convert back to natural  
gas.  
The engine has been fitted with a fuel carburetion  
system that meets the specifications of the 1997  
California Air Resources Board for tamper-proof  
dual fuel systems. The unit will run on natural gas or  
LP gas, but it has been factory set to run on natural  
gas. Should the primary fuel need to be changed to  
LP gas, the fuel system needs to be reconfigured. See  
Section 1.8 for instructions on reconfiguration of the  
fuel system.  
Figure 1.4 – Demand Regulator  
LP OUTLET  
PORT  
LP OUTLET  
PORT  
NG OUTLET  
PORT  
NG OUTLET  
PORT  
Recommended fuels should have a Btu content of at  
least 1,000 Btus per cubic foot for natural gas; or at  
least 2,520 Btus per cubic foot for LP gas. Ask the  
fuel supplier for the Btu content of the fuel.  
Required fuel pressure for natural gas is 5 inches  
to 7 inches water column (0.18 to 0.25); and for  
liquid propane vapor, 10 inches to 12 inches of  
water column (0.36 to 0.43 psi).  
A seperate gas line and regulator may be need-  
NG FUEL SYSTEM  
LP FUEL SYSTEM  
ed to assure proper gas pressure to the genera-  
tor. Low gas pressure can cause hard starting  
and could affect engine durability.  
1.10 LOCATION  
‹
1.10.1 GENERATOR  
1.8 FUEL CONSUMPTION  
Install the generator set, in its protective enclosure,  
outdoors, where adequate cooling and ventilating air  
is always available. Consider these factors:  
Model #  
Nat. Gas (*)  
LP Vapor (**)  
1/2 Load Full Load 1/2 Load  
Full Load  
2.15/86.4  
04916  
115  
202  
1.38/55.6  
• Install the unit where air inlet and outlet open-  
ings will not become obstructed by leaves, grass,  
snow, etc. If prevailing winds will cause blowing or  
drifting, consider using a windbreak to protect the  
unit.  
*Natural gas is in cubic feet per hour.  
**LP is in gallons per hour/cubic feet per hour.  
DANGER  
• Install the generator on high ground where water  
Gaseous fuels such as natural gas and liquid  
propane (LP) gas are highly explosive. Even the  
slightest spark can ignite such fuels and cause  
an explosion. No leakage of fuel is permitted.  
Natural gas, which is lighter than air, tends to  
collect in high areas. LP gas is heavier than air  
and tends to settle in low areas.  
levels will not rise and endanger it.  
• Allow sufficient room on all sides of the generator  
for maintenance and servicing. A good rule is to  
allow three feet of space on all sides.  
• Where strong prevailing winds blow from one  
direction, face the generator air inlet openings to  
the prevailing winds.  
1.9 RECONFIGURING THE  
• Install the generator as close as possible to the fuel  
supply, to reduce the length of piping.  
FUEL SYSTEM  
• Install the generator as close as possible to  
the transfer switch. HOWEVER, REMEMBER  
THAT LAWS OR CODES MAY REGULATE THE  
DISTANCE.  
To reconfigure the fuel system from NG to LP,  
follow these steps:  
1. Turn the main gas supply off.  
2. Remove the carburetor fuel hose and the brass  
hose fitting from the NG (right) outlet port of the  
demand regulator (Figure 1.4).  
The genset must be installed on a level surface. The  
base frame must be level within two (2) inches all  
around.  
7
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Section 1 — General Information  
Air-cooled 11 kW Generators  
NOTE:  
‹
1.10.2 TRANSFER SWITCH  
The generator is equipped with a battery trickle  
charger that is active when the unit is set up for  
automatic operation. With the battery installed  
and utility power source voltage available to the  
transfer switch, the battery receives a trickle  
charge while the engine is not running, to prevent  
self-discharge. The trickle charger is designed to  
help extend the life of the battery by maintain-  
ing the battery when the unit is not running. The  
trickle charge feature cannot be used to recharge  
a discharged battery.  
This generator should only be installed with a com-  
patible transfer switch. A range of transfer switches  
are offered by the manufacturer.  
1.11 BATTERY INSTALLATION  
If the AUTO/OFF/MANUAL switch is not set to its  
OFF position, the generator can crank and start  
as soon as the battery cables are connected. If  
the utility power supply is not turned off, spark-  
ing can occur at the battery posts and cause an  
explosion.  
1.12 THE BATTERY  
Servicing of the battery is to be performed or super-  
vised by personnel knowledgeable of batteries and  
the required precautions. Keep unauthorized person-  
nel away from batteries.  
Fill the battery with the proper electrolyte fluid if  
necessary and have the battery fully charged before  
installing it.  
When replacing the battery, use the following type of  
battery: Group 26/26R 12-volt DC, negative ground  
battery with a rating of 525 cold-cranking amps mini-  
mum at -17.8º C (0º F). When using a maintenance-  
free battery, it is not necessary to check the specific  
gravity or electrolyte level. Have these procedures  
performed at the intervals specified in the “Service  
Schedule.” A negative ground system is used. Battery  
connections are shown on the wiring diagrams. Make  
sure the battery is correctly connected and terminals  
are tight. Observe battery polarity when connecting  
the battery to the generator set.  
Before installing and connecting the battery, complete  
the following steps:  
1. Set the generator's AUTO/OFF/MANUAL switch to  
OFF.  
2. Turn off utility power supply to the transfer  
switch.  
3. Remove the 7.5A and 15A fuses from the genera-  
tor control panel.  
Battery cables were factory connected at the genera-  
tor (Figure 1.5). Connect cables to battery posts as  
follows:  
4. Connect the red battery cable (from starter con-  
tactor) to the battery post indicated by a positive,  
POS or (+).  
5. Connect the black battery cable (from frame  
ground) to the battery post indicated by a nega-  
tive, NEG or (—).  
DANGER  
Do not dispose of the battery in a fire. The  
battery is capable of exploding.  
A battery presents a risk of electrical shock  
and high short circuit current. The following pre-  
cautions are to be observed when working on  
batteries:  
NOTE:  
Damage will result if battery connections are made  
in reverse.  
• Remove the 7.5A and 15A fuses from the genera-  
tor control panel.  
• Remove watches, rings or other metal objects;  
• Use tools with insulated handles;  
• Wear rubber gloves and boots;  
• Do not lay tools or metal parts on top of the  
battery; and  
Figure 1.5 – Battery Cable Connections  
• Disconnect charging source prior to connecting or  
disconnecting battery terminals.  
Do not open or mutilate the battery. Released  
electrolyte has been known to be harmful to the  
skin and eyes, and to be toxic.  
The electrolyte is a dilute sulfuric acid that is  
harmful to the skin and eyes. It is electrically  
conductive and corrosive.  
8
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 11 kW Generators  
The following procedures are to be observed:  
• Wear full eye protection and protective clothing;  
• Where electrolyte contacts the skin, wash it off  
immediately with water;  
• Where electrolyte contacts the eyes, flush  
thoroughly and immediately with water and seek  
medical attention; and  
• Spilled electrolyte is to be washed down with an  
acid neutralizing agent. A common practice is to  
use a solution of 1 pound (500 grams) bicarbonate  
of soda to 1 gallon (4 liters) of water. The bicar-  
bonate of soda solution is to be added until the  
evidence of reaction (foaming) has ceased. The  
resulting liquid is to be flushed with water and the  
area dried.  
Never operate the engine with the oil level  
below the “ADD” mark on the dipstick. Doing  
this could damage the engine.  
2.2 CHECK TRANSFER SWITCH  
OPERATION  
Refer to the transfer switch owner’s manual for man-  
ual operation procedures.  
DANGER  
Do not attempt manual transfer switch opera-  
tion until all power voltage supplies to the  
transfer switch have been positively turned off.  
Failure to turn off all power voltage supplies  
will result in extremely hazardous and possibly  
fatal electrical shock.  
Lead-acid batteries present a risk of fire because  
they generate hydrogen gas. The  
following procedures are to be followed:  
• DO NOT SMOKE when near the battery;  
• DO NOT cause flame or spark in battery area; and  
• Discharge static electricity from body before touch-  
ing the battery by first touching a grounded metal  
surface.  
2.3 ELECTRICAL CHECKS  
Complete electrical checks as follows:  
1. Set the generator's main circuit breaker to its  
OFF (or open) position.  
Be sure the AUTO/OFF/MANUAL switch is set to  
the OFF position before connecting the battery  
2. Set the generator's AUTO/OFF/MANUAL switch to  
cables. If the switch is set to AUTO or MANUAL,  
the generator can crank and start as soon as the  
battery cables are connected.  
the OFF position.  
3. Turn OFF all loads connected to the transfer  
switch terminals T1 and T2.  
4. Turn on the utility power supply to the transfer  
switch using the means provided (such as a utility  
main line circuit breaker).  
Be sure the utility power supply is turned off  
and the 7.5A and 15A fuses are removed from  
the generator control panel, or sparking may  
occur at the battery posts as the cables are  
attached and cause an explosion.  
DANGER  
The transfer switch is now electrically “hot.”  
2.1 BEFORE INITIAL START-UP  
Contact with “hot” parts will result in extremely  
Before starting, complete the following:  
hazardous and possibly fatal electrical shock.  
Proceed with caution.  
5. Use an accurate AC voltmeter to check utility  
power source voltage across transfer switch ter-  
minals N1 and N2. Nominal line-to-line voltage  
should be 240 volts AC.  
6. Check utility power source voltage across termi-  
nals N1 and the transfer switch neutral lug; then  
across terminal N2 and neutral. Nominal line-to-  
neutral voltage should be 120 volts AC.  
1. Set the generator’s main circuit breaker to its  
OFF (or OPEN) position.  
2. Set the generator's AUTO/OFF/MANUAL switch to  
the OFF position.  
3. Turn OFF the utility power supply to the transfer  
switch using the means provided (such as the  
utility main line circuit breaker).  
4. Turn OFF all loads connected to the transfer  
switch terminals T1 and T2.  
5. Check the engine crankcase oil level and, if neces-  
sary, fill to the dipstick FULL mark with the rec-  
ommended oil. Do not fill above the FULL mark.  
6. Check the fuel supply. Gaseous fuel lines must  
have been properly purged and leak tested in  
accordance with applicable fuel-gas codes. All  
fuel shutoff valves in the fuel supply lines must be  
open.  
7. When certain that utility supply voltage is compat-  
ible with transfer switch and load circuit ratings,  
turn OFF the utility power supply to the transfer  
switch.  
8. On the generator panel, set the AUTO/OFF/  
MANUAL switch to MANUAL. The engine should  
crank and start.  
9. Let the engine warm up for about five minutes to  
allow internal temperatures to stabilize. Then, set  
the generator’s main circuit breaker to its ON (or  
.
closed) position.  
9
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Section 2 — Post Installation Start-up and Adjustments  
Air-cooled 11 kW Generators  
6. Set the generator's AUTO/OFF/MANUAL switch  
DANGER  
to MANUAL. The engine should crank and start  
immediately.  
Proceed with caution! Generator power voltage  
is now supplied to the transfer switch. Contact  
with live transfer switch parts will result in dan-  
gerous and possibly fatal electrical shock.  
7. Let the engine stabilize and warm up for a few  
minutes.  
8. Set the generator’s main circuit breaker to its ON  
(or closed) position. Loads are now powered by  
the standby generator.  
9. Turn ON electrical loads connected to transfer  
switch T1 and T2. Apply an electrical load equal  
to the full rated wattage/amperage capacity of the  
installed generator.  
10. Connect an accurate AC voltmeter and a frequen-  
cy meter across terminal lugs E1 and E2. Voltage  
should be greater than 230 volts; frequency  
should be greater than 58 Hertz.  
11. Let the generator run at full rated load for 20-30  
minutes. Listen for unusual noises, vibration or  
other indications of abnormal operation. Check  
for oil leaks, evidence of overheating, etc.  
12. When testing under load is complete, turn OFF  
electrical loads.  
10. Connect an accurate AC voltmeter and a fre-  
quency meter across transfer switch terminal  
lugs E1 and E2. Voltage should be 242-252 volts;  
frequency should read about 61-63 Hertz.  
11. Connect the AC voltmeter test leads across ter-  
minal lug E1 and neutral; then across E2 and  
neutral. In both cases, voltage reading should be  
121-126 volts AC.  
12. Set the generator’s main circuit breaker to its  
OFF (or open) position. Let the engine run at no-  
load for a few minutes to stabilize internal engine  
generator temperatures.  
13. Set the generator's AUTO/OFF/MANUAL switch to  
OFF. The engine should shut down.  
NOTE:  
It is important not to proceed until certain that  
generator AC voltage and frequency are correct  
and within the stated limits. Generally, if both AC  
frequency and voltage are high or low, the engine  
governor requires adjustment. If frequency is cor-  
rect, but voltage is high or low, the generator’s  
voltage regulator requires adjustment.  
13. Set the generator's main circuit breaker to its  
OFF (or open) position.  
14. Let the engine run at no-load for a few minutes.  
15. Set the AUTO/OFF/MANUAL switch to OFF. The  
engine should shut down.  
2.5 CHECKING AUTOMATIC  
OPERATION  
2.4 GENERATOR TESTS UNDER LOAD  
To test the generator set with electrical loads applied,  
proceed as follows:  
To check the system for proper automatic operation,  
proceed as follows:  
1. Set generator’s main circuit breaker to its OFF  
(or open) position.  
1. Set generator’s main circuit breaker to its OFF  
(or open) position.  
2. Check that the AUTO/OFF/MANUAL switch is set  
2. Turn OFF all loads connected to the transfer  
to OFF.  
switch terminals T1 and T2.  
3. Turn OFF the utility power supply to the transfer  
switch, using means provided (such as a utility  
main line circuit breaker).  
4. Manually set the transfer switch to the UTILITY  
position, i.e., load terminals connected to the util-  
ity power source side.  
3. Set the generator's AUTO/OFF/MANUAL switch to  
OFF.  
4. Turn OFF the utility power supply to the transfer  
switch, using the means provided (such as a util-  
ity main line circuit breaker).  
5. Turn ON the utility power supply to the transfer  
switch, using the means provided (such as a util-  
ity main line circuit breaker).  
6. Set the AUTO/OFF/MANUAL switch to AUTO. The  
system is now ready for automatic operation.  
7. Turn OFF the utility power supply to the transfer  
switch.  
With the AUTO/OFF/MANUAL switch at AUTO, the  
engine should crank and start when the utility source  
power is turned OFF. After starting, the transfer  
switch should connect load circuits to the standby  
side. Let the system go through its entire automatic  
sequence of operation.  
Do not attempt manual transfer switch opera-  
tion until all power voltage supplies to the  
transfer switch have been positively turned off.  
Failure to turn off all power voltage supplies  
will result in extremely hazardous and possibly  
fatal electrical shock.  
5. Manually set the transfer switch to the STANDBY  
position, e.g., load terminals connected to the  
generator's E1/E2 terminals. The transfer switch  
operating lever should be down.  
10  
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Section 3 — Operation  
Air-cooled 11 kW Generators  
With the generator running and loads powered by  
generator AC output, turn ON the utility power supply  
to the transfer switch. The following should occur:  
4. Run the unit for one hour at 25% rated load.  
5. Run the unit for one hour at 50% rated load.  
6. Run the unit for one hour at 75% rated load.  
7. Run the unit for one hour at 100% rated load.  
8. Turn ON the utility power supply to the transfer  
switch, which will allow the transfer switch to  
transfer back to utility power. The unit will con-  
tinue to run for one minute and then shut down.  
9. Allow the unit to cool.  
10. Set the generator's AUTO/OFF/MANUAL switch  
to OFF. Remove the 7.5A and 15A fuses from the  
generator control panel. Disconnect the battery  
cables as outlined in “General Hazards” (page  
2).  
• After about six seconds, the switch should transfer  
loads back to the utility power source.  
• About one minute after retransfer, the engine  
should shut down.  
2.6 VOLTAGE REGULATOR  
ADJUSTMENT  
With the frequency between 60-60.5 Hertz, slowly  
turn the slotted potentiometer (Figure 2.1) until line  
voltage reads 247-252 volts.  
11. Drain the oil and remove the oil filter. Replace  
the oil filter according to Section 4.4, “Changing  
the Oil Filter”. Replace the oil with synthetic oil  
as recommended in Section 4.3, “Changing the  
Engine Oil”.  
12. Reconnect the battery cables as outlined in  
“General Hazards” (page 2) and insert the 5A and  
15A fuses into the generator control panel. The  
generator is now ready for service.  
NOTE:  
The access panel on top of the control panel must  
be removed to adjust the voltage regulator.  
Figure 2.1 – Voltage Adjustment Potentiometer  
3.2 USING THE AUTO/OFF/MANUAL  
SWITCH (FIGURE 3.1)  
‹
3.2.1 “AUTO” POSITION  
Selecting this switch position activates fully automat-  
ic system operation. It also allows personnel to start  
and exercise the engine every seven days with the set-  
ting of the exercise timer (see Section 3.5).  
Figure 3.1 – Generator Control Panel  
NOTE:  
The voltage regulator is housed inside the gen-  
erator's control panel. The regulator maintains a  
voltage in direct proportion to frequency at a 2-to-  
1 ratio. For example, at 62 Hertz, line-to-neutral  
voltage will be 124 volts.  
3.1 BREAK-IN PROCEDURE  
Once the unit has been installed and all electrical  
checks have been made, it is strongly recommended  
that the following “Break-in Procedure” be completed  
to ensure correct generator operation in the future.  
1. Set the generator’s AUTO/OFF/MANUAL switch to  
AUTO.  
2. Turn OFF the utility power supply to the transfer  
switch using the means provided (such as a utility  
main line circuit breaker).  
3. The unit will start, and the transfer switch will  
transfer to standby.  
11  
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Section 3 — Operation  
Air-cooled 11 kW Generators  
‹
3.2.2 “OFF” POSITION  
3.4 SEQUENCE OF AUTOMATIC  
This switch position shuts down the engine. This  
position also prevents automatic operation.  
OPERATION  
The generator’s control panel houses a control logic  
circuit board. This board constantly monitors util-  
ity power source voltage. Should that voltage drop  
below a preset level, circuit board action will signal  
the engine to crank and start. After the engine starts,  
the circuit board signals the transfer switch to acti-  
vate and connect load circuits to the standby power  
supply (load terminal lugs T1/T2 connect to terminal  
lugs E1/E2).  
‹
3.2.3 “MANUAL” POSITION  
Set the switch to Manual to crank and start the  
engine. Transfer to standby power will not occur  
unless there is a utility failure.  
With the switch set to AUTO, the engine may  
Upon restoration of utility source voltage above a  
preset level, generator circuit board action signals the  
transfer switch to transfer loads back to that power  
supply. After retransfer, the engine is signalled to shut  
down.  
crank and start at any time without warning.  
Such automatic starting normally occurs when  
utility power source voltage drops below a pre-  
set level or during the normal exercise cycle. To  
prevent possible injury that might be caused  
by such sudden starts, always set the switch to  
OFF and remove the fuses before working on or  
around the generator or transfer switch. Then,  
place a “DO NOT OPERATE” tag on the generator  
panel and on the transfer switch.  
The actual sequence of operation is controlled by  
sensors and timers on a control logic circuit board,  
as follows:  
A. Utility Voltage Dropout Sensor  
• This sensor monitors utility source voltage.  
• If utility source voltage drops below about 70  
percent of the nominal supply voltage, the sensor  
energizes a 15-second timer.  
• Once the timer has expired, the engine will crank  
and start.  
3.3 AUTOMATIC TRANSFER  
OPERATION  
To select automatic operation, do the following:  
B. Engine Warm-up Time Delay  
1. Make sure the transfer switch main contacts are  
set to their “Utility” position, i.e., loads connected  
to the utility power source (Figure 3.2).  
2. Be sure that normal utility power source voltage  
is available to transfer switch terminal lugs N1  
and N2.  
• This mechanism lets the engine warm up for  
about 10 seconds before the load is transferred  
to the standby source.  
C. Utility Voltage Pickup Sensor  
• This sensor monitors utility power supply volt-  
age. When that voltage is restored above 70 per-  
cent of the nominal source voltage, a retransfer  
time delay starts timing.  
3. Set the generator’s AUTO/OFF/MANUAL switch to  
AUTO.  
4. Set the generator’s main circuit breaker to its ON  
(or closed) position.  
D. Retransfer Time Delay  
With the preceding steps complete, the generator will  
start automatically when utility source voltage drops  
below a preset level. After the unit starts, loads are  
transferred to the standby power source. Refer to  
Section 3.4, “Sequence of Automatic Operation.”  
• This timer runs for about 15 seconds.  
• At end of a 15-second delay, circuit board  
action de-energizes transfer relay in the transfer  
switch.  
• Retransfer to utility power source then occurs.  
E. Engine Cool-down Timer  
• When the load is transferred back to utility power  
source, the engine cool-down timer starts tim-  
ing.  
• The timer will run for about one minute, and the  
generator will then shut down.  
12  
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Section 3 — Operation  
Air-cooled 11 kW Generators  
Figure 3.2 – Low Oil Pressure and  
High Temperature Switches  
3.5 SETTING THE EXERCISE TIMER  
This generator is equipped with an exercise timer.  
Once it is set, the generator will start and exercise  
once every seven days, on the day of the week and at  
the time of day the following sequence is completed.  
During this exercise period, the unit runs for approx-  
imately 12 minutes and then shuts down. Transfer of  
loads to the generator output does not occur during  
the exercise cycle.  
A switch on the control panel (see Figure 3.1) per-  
mits selection of the day and time for the system to  
exercise. At the chosen time, perform the following  
sequence to select the desired day and time of day the  
system will exercise.  
Place the AUTO/OFF/MANUAL switch in the AUTO  
position. Push and hold the “Set Exercise Time”  
switch to the ON position for approximately three  
seconds and release. All five red LED’s will flash for  
10 seconds. The unit will perform the standard exer-  
cise sequence, then shut down. The generator will  
now exercise every seven days at the time set.  
‹
3.6.3 OVERCRANK  
This feature prevents the generator from damaging  
itself when it continually attempts to start and anoth-  
er problem, such as no fuel supply, prevents it from  
starting. The unit will crank and rest for a preset  
time limit. Then, it will stop cranking, and the LED  
on the generator control panel will light indicating an  
overcrank failure. The AUTO/OFF/MANUAL switch  
will need to be set to OFF and then back to AUTO to  
reset the generator control board.  
NOTE:  
The exerciser will only work in the AUTO mode  
and will not work unless this procedure is per-  
formed. The exerciser will need to be reset every  
time the 12-volt battery is disconnected and then  
reconnected.  
3.6 PROTECTION SYSTEMS  
NOTE:  
‹
3.6.1 LOW OIL PRESSURE SWITCH  
If the fault is not repaired, the overcrank feature  
will continue to activate.  
This switch (Figure 3.2) has normally closed con-  
tacts that are held open by engine oil pressure dur-  
ing cranking and operating. Should oil pressure  
drop below the 8 psi range, switch contacts close,  
and the engine shuts down. The unit should not be  
restarted until oil is added. The AUTO/OFF/MANUAL  
switch must then be turned to OFF and then back to  
AUTO.  
3.6.3.1 Approximate Crank Cycle Times  
• 15 seconds ON  
• 7 seconds OFF  
• 7 seconds ON  
• 7 seconds OFF  
• Repeat for 45 seconds  
Approximately 90 seconds total  
‹
3.6.2 HIGH TEMPERATURE SWITCH  
This switch’s contacts (Figure 3.3) close if the tem-  
perature should exceed approximately 132º C (270º  
F), initiating an engine shutdown. The generator will  
automatically restart and the LED on the generator  
control panel will reset once the temperature has  
returned to a safe operating level.  
‹
3.6.4 OVERSPEED  
This feature protects the generator from damage by  
shutting it down if it happens to run faster than the  
preset limit. This protection also prevents the gen-  
erator from supplying an output that could poten-  
tially damage appliances connected to the generator  
circuit. Contact the nearest Authorized Dealer if this  
failure occurs.  
13  
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Section 4 — Maintenance  
Air-cooled 11 kW Generators  
‹
3.6.5 LOW BATTERY  
4.2 CHECKING THE ENGINE  
The microprocessor will continually monitor the bat-  
tery voltage and turn on the Low Battery LED if the  
battery voltage falls below 11.0 volts for one minute.  
Low battery voltage is a non-latching alarm, which  
will automatically clear if the battery voltage rises  
above 11.0 volts.  
OIL LEVEL  
For oil capacities, see “Specifications,” Section 1.5.  
For engine oil recommendations, see Section 4.3.1.  
To check the engine oil level, proceed as follows  
(Figures 4.2):  
1. Start the generator by moving the AUTO/ OFF/  
MANUAL switch to the MANUAL position. Allow  
it to run for a short while and then shut it down  
by moving the switch to the OFF position.  
2. Remove the dipstick and wipe it dry with a  
clean cloth.  
3. Install the dipstick; then, remove it again. The oil  
level should be at the dipstick “Full” mark. If nec-  
essary, add oil to the “Full” mark only. DO NOT  
FILL ABOVE THE “FULL” MARK.  
The control system will not attempt to start the  
engine if there is a low battery condition, however,  
if the engine is already running when the low bat-  
tery condition occurs, the engine will continue to  
run as long as possible.  
Battery voltage is NOT monitored during the crank  
cycle.  
4.1 SYSTEM FUSE  
The generator panel’s 15 amp fuse (Figure 4.1) pro-  
tects the DC control circuit against overload. The fuse  
is wired in series with the battery output lead to the  
panel. If the fuse element has melted open, the engine  
cannot crank or start. Replace the fuse using only an  
identical 15-amp replacement.  
Never operate the engine with the oil level  
below the “Add” mark on the dipstick. Doing  
this could damage the engine.  
4. Install the dipstick.  
5. Reset the AUTO/OFF/MANUAL switch to its origi-  
‹
4.1.1 7.5 AMP FUSE  
nal position.  
The generator panel’s 7.5 amp fuse protects the  
accessory outlet against overload. If the fuse element  
has melted open, there will not be power at the acces-  
sory outlet. Replace the fuse using only an identical  
7.5 amp fuse. To remove fuse, push cap down and  
rotate counterclockwise.  
Figure 4.2 — Oil Dipstick and Fill  
Oil Fill  
Figure 4.1 – Generator Control Panel  
Oil Dipstick  
4.3 CHANGING THE ENGINE OIL  
‹
4.3.1 ENGINE OIL RECOMMENDATIONS  
Use oil of American Petroleum Institute (API) Service  
Class SG, SH or SJ. Use all season SAE 5W-30  
Synthetic oil. Organic break-in oil is required before  
using synthetic oil.  
NOTE:  
The unit is supplied with “break-in” oil. See the  
“Break-in Procedure,” Section 3.1, for the first  
required oil change.  
14  
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Section 4 — Maintenance  
Air-cooled 11 kW Generators  
4.5 CHANGING THE ENGINE  
AIR CLEANER  
Any attempt to crank or start the engine before  
it has been properly serviced with the recom-  
mended oil may result in an engine failure.  
See Figure 1.3, for the location of the air cleaner. Use  
the following procedure (Figure 4.4):  
1. Turn the two screws counterclockwise to loosen.  
2. Remove the cover and air filter.  
‹
4.3.2 OIL CHANGE PROCEDURE  
3. Wipe away dust or debris from inside of the air  
To change the oil, proceed as follows:  
box and around edges.  
1. Run the engine until it is thoroughly warmed up  
then shut OFF the engine.  
2. Immediately after the engine shuts OFF, pull the  
oil drain hose (Figure 4.3) free of its retaining  
clip. Remove the cap from the hose and drain the  
oil into a suitable container.  
3. After the oil has drained, replace the cap onto the  
end of the oil drain hose. Retain the hose in the  
clip.  
4. Install the new air cleaner into the air box.  
5. Install the cover. Turn the two cover screws clock-  
wise to tighten.  
See the “Service Schedule,” Section 4.13, for air  
cleaner maintenance. See Section 1.6.1 for air filter  
replacement part number.  
Figure 4.4 — Engine Air Cleaner  
4. Refill with the proper recommended oil (see  
Section 4.3.1). See Section 1.6.2 for oil capaci-  
ties.  
Figure 4.3 – Oil Drain Hose and Filter  
Loosen  
Filter  
Screw  
Cover  
Oil Drain Hose  
Oil Filter  
4.6 SPARK PLUGS  
Reset the spark plug gaps or replace the spark plugs  
as necessary. See Section 4.13 for maintenance  
requirements.  
4.4 CHANGING THE OIL FILTER  
Change the engine oil filter as follows:  
1. Clean the area around the base of the spark plugs  
to keep dirt and debris out of the engine. Clean  
by scraping or washing using a wire brush and  
commercial solvent. Do not blast the spark plugs  
to clean.  
2. Remove the spark plugs and check the condition.  
Replace the spark plugs if worn or if reuse is  
questionable. See Section 4.13 for recommended  
inspection.  
3. Check the spark plug gap using a wire feeler  
gauge. Adjust the gap to 0.76 mm (0.030 inch)  
by carefully bending the ground electrode (Figure  
4.5).  
1. With the oil drained, remove the old oil filter by  
turning it counterclockwise.  
2. Apply a light coating of clean engine oil to the  
gasket of the new filter. See Section 1.6.1 for rec-  
ommended filter.  
3. Screw the new filter on by hand until its gasket  
lightly contacts the oil filter adapter. Then, tighten  
the filter an additional 3/4 to one turn (Figure  
4.3).  
4. Refill with the proper recommended oil (see  
Section 4.3.1). See Section 1.6.2 for oil capaci-  
ties.  
5. Start the engine and check for leaks.  
15  
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Section 4 — Maintenance  
Air-cooled 11 kW Generators  
• Where electrolyte contacts the eyes, flush  
thoroughly and immediately with water and seek  
medical attention; and  
Figure 4.5 – Setting the Spark Plug Gap  
• Spilled electrolyte is to be washed down with an  
acid neutralizing agent. A common practice is to  
use a solution of 1 pound (500 grams) bicarbonate  
of soda to 1 gallon (4 liters) of water. The bicar-  
bonate of soda solution is to be added until the  
evidence of reaction (foaming) has ceased. The  
resulting liquid is to be flushed with water and the  
area dried.  
Lead-acid batteries present a risk of fire because  
they generate hydrogen gas. The  
following procedures are to be followed:  
4.7 BATTERY MAINTENANCE  
• DO NOT SMOKE when near the battery;  
• DO NOT cause flame or spark in battery area; and  
• Discharge static electricity from body before touch-  
ing the battery by first touching a grounded metal  
surface.  
The battery should be inspected per the “Service  
Schedule,” Section 4.13. The following procedure  
should be followed for inspection:  
1. Inspect the battery posts and cables for tightness  
and corrosion. Tighten and clean as necessary.  
2. Check the battery fluid level of unsealed batteries  
and, if necessary, fill with Distilled Water Only. Do  
not use tap water in batteries.  
3. Have the state of charge and condition checked.  
This should be done with an automotive-type bat-  
tery hydrometer.  
Be sure the AUTO/OFF/MANUAL switch is set to  
the OFF position before connecting the battery  
cables. If the switch is set to AUTO or MANUAL,  
the generator can crank and start as soon as the  
battery cables are connected.  
Be sure the utility power supply is turned off  
and the 5A and 15A fuses are removed from the  
DANGER  
generator control panel, or sparking may occur  
at the battery posts as the cables are attached  
and cause an explosion.  
Do not dispose of the battery in a fire. The  
battery is capable of exploding.  
A battery presents a risk of electrical shock  
cautions are to be observed when working on  
batteries:  
• Remove the 7.5A and 15A fuses from the genera-  
tor control panel.  
• Remove watches, rings or other metal objects;  
• Use tools with insulated handles;  
• Wear rubber gloves and boots;  
• Do not lay tools or metal parts on top of the  
battery; and  
• Disconnect charging source prior to connecting or  
disconnecting battery terminals.  
4.8 ADJUSTING GT-990 VALVE  
and high short circuit current. The following pre-  
CLEARANCE  
After the first six months of operation, adjust the  
valve clearance in the engine (Figure 4.6).  
Important: If feeling uncomfortable about doing  
this procedure or the proper tools are not available,  
please contact the Authorized Dealer for service  
assistance. This is a very important step to insure  
longest life for the engine.  
To adjust valve clearance:  
• Make sure the engine is at room temperature  
(between 60° and 80° F).  
• Make sure that the spark plug(s) are removed.  
• Remove the four screws attaching the valve cover  
with a #2 or #3 phillips screwdriver.  
Do not open or mutilate the battery. Released  
electrolyte has been known to be harmful to the  
• Make sure the piston is at Top Dead Center (TDC)  
of its compression stroke (both valves closed). To  
get the piston at TDC, remove the screen at the top  
of the intake scroll to gain access to the intake fan.  
Rotate the engine by hand by rotating the fan while  
watching the piston through the spark plug hole.  
The piston should move back and forth. The pis-  
ton is at TDC when it is as forward as it can go.  
skin and eyes, and to be toxic.  
The electrolyte is a dilute sulfuric acid that is  
harmful to the skin and eyes. It is electrically  
conductive and corrosive. The following  
procedures are to be observed:  
• Wear full eye protection and protective clothing;  
• Where electrolyte contacts the skin, wash it off  
immediately with water;  
16  
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Section 4 — Maintenance  
Air-cooled 11 kW Generators  
• Loosen the rocker jam nut. Use an 10mm allen  
wrench to turn the pivot ball stud while checking  
clearance between the rocker arm and the valve  
stem with a feeler gauge. Correct clearance is  
0.002-0.004 inch (0.05-0.1 mm).  
Figure 4.7 – Cooling Vent Locations  
Overhead View  
AIR  
OUTLET  
NOTE:  
Hold the rocker arm jam nut in place as the pivot  
ball stud is turned.  
When valve clearance is correct, hold the pivot ball  
stud in place with the allen wrench and tighten the  
rocker arm jam nut. Tighten the jam nut to 174  
in.lbs. torque. After tightening the jam nut, recheck  
valve clearance to make sure it did not change.  
Figure 4.6 - Valve Clearance Adjustment  
Jam Nut  
The maximum ambient temperature for the gen-  
erator is 40° C (104° F).  
Valve Stem  
4.10 ATTENTION AFTER SUBMERSION  
If the generator has been submerged in water,  
it MUST NOT be started and operated. Following any  
submersion in water, have an Authorized Dealer thor-  
oughly clean and dry the generator.  
4.11 CORROSION PROTECTION  
Periodically wash and wax the enclosure using auto-  
motive type products. Frequent washing is recom-  
mended in salt water/coastal areas. Spray engine  
linkages with a light oil such as WD-40®.  
Pivot Ball Stud  
Rocker Arm  
• Install new valve cover gasket.  
• Re-attach the valve cover.  
NOTE:  
4.12 OUT OF SERVICE PROCEDURE  
Start all four screws before tightening or it will not  
be possible to get all the screws in place. Make  
sure the valve cover gasket is in place.  
‹
4.12.1 REMOVAL FROM SERVICE  
If the generator cannot be exercised every seven days,  
and will be out of service longer than 90 days, pre-  
pare the generator for storage as follows:  
• Re-attach the spark plug wire to the spark plug.  
• Repeat the process for the other cylinder.  
1. Start the engine and let it warm up.  
2. Close the fuel shutoff valve in the fuel supply line  
and allow the unit to shut down.  
4.9 COOLING SYSTEM  
Air inlet and outlet openings in the generator com-  
partment must be open and unobstructed for con-  
tinued proper operation. This includes such obstruc-  
tions as high grass, weeds, brush, leaves and snow.  
3. Once the unit has shut down, it will signal a low  
oil fault.  
4. Set the AUTO/OFF/MANUAL switch to OFF and  
turn off the utility power to the transfer switch.  
Remove the 7.5A and 15A fuses from the genera-  
tor control panel. Disconnect the battery cables  
as outlined in “General Hazards” (page 2).  
5. While the engine is still warm from running,  
drain the oil completely. Refill the crankcase with  
oil. See ”Engine Oil Recommendations,” Section  
4.3.1.  
Without sufficient cooling and ventilating air flow, the  
engine/generator quickly overheats, which causes it  
to quickly shut down. (See Figure 4.7 for vent loca-  
tions.)  
The exhaust from this product gets extremely  
hot and remains hot after shutdown. High grass,  
weeds, brush, leaves, etc. must remain clear of  
the exhaust. Such materials may ignite and burn  
from the heat of the exhaust system.  
6. Attach a tag to the engine indicating the viscosity  
and classification of the oil in the crankcase.  
17  
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Section 4 — Maintenance  
Air-cooled 11 kW Generators  
7. Remove the spark plug(s) and spray fogging  
agent into the spark plug(s) threaded openings.  
Reinstall and tighten the spark plug(s).  
8. Remove the battery and store it in a cool, dry  
room on a wooden board. Never store the battery  
on any concrete or earthen floor.  
4. Clean and wipe the entire generator.  
5. Remove the 7.5A and 15A fuses from the genera-  
tor control panel. Reconnect the battery. Observe  
battery polarity. Damage may occur if the battery  
is connected incorrectly.  
6. Open the fuel shutoff valve.  
9. Clean and wipe the entire generator.  
7. Insert the 7.5A and 15A fuses into the generator  
control panel. Start the unit by moving the AUTO/  
OFF/MANUAL switch to MANUAL. Allow the unit  
to warm up thoroughly.  
‹
4.12.2 RETURN TO SERVICE  
To return the unit to service after storage, proceed  
as follows:  
8. Stop the unit by setting the AUTO/OFF/MANUAL  
switch to OFF.  
1. Verify that utility power is turned off and that the  
AUTO/OFF/MANUAL switch is set to OFF.  
9. Turn on the utility power to the transfer switch.  
10. Set the AUTO/OFF/MANUAL switch to AUTO.  
11. The generator is now ready for service.  
NOTE:  
2. Check the tag on the engine for oil viscosity and  
classification. Verify that the correct recommend-  
ed oil is used in the engine (see Section 4.3.1). If  
necessary, drain and refill with the proper oil.  
3. Check the state of the battery. Fill all cells of  
unsealed batteries to the proper level with dis-  
tilled water. DO NOT USE TAP WATER IN THE  
BATTERY. Recharge the battery to 100 percent  
state of charge, or, if defective, replace the battery.  
See “Specifications,” Section 1.6, for type and  
size.  
If the battery was dead or disconnected, the exer-  
cise timer must be reset.  
18  
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Section 4 — Maintenance  
Air-cooled 11 kW Generators  
4.13 SERVICE SCHEDULE  
ATTENTION: It is recommended that all service work  
be performed by the nearest Authorized Dealer.  
SYSTEM/COMPONENT  
PROCEDURE  
FREQUENCY  
X = Action  
Inspect  
Change  
Clean  
W = Weekly  
M = Monthly  
Y = Yearly  
R = Replace as Necessary  
* = Notify Dealer  
if Repair is Needed.  
FUEL  
Fuel lines and connections*  
X
X
M
M
LUBRICATION  
Oil level  
Oil  
X
X
AFTER BREAK-IN,  
AND Y  
Oil filter  
AFTER BREAK-IN,  
AND Y  
COOLING  
Enclosure louvers  
BATTERY  
X
X
W
Remove corrosion,  
ensure dryness  
X
X
X
X
M
M
Clean and tighten  
battery terminals  
Check charge state  
X
X
R
R
EVERY 6 M  
EVERY 6 M  
Electrolyte level  
(unsealed batteries only)*  
ENGINE AND MOUNTING  
Air cleaner  
X
X
R
R
Y
Y
Spark plug(s)  
GENERAL CONDITION  
Vibration, Noise, Leakage,  
Temperature*  
X
M
Y
COMPLETE TUNE-UP*  
TO BE COMPLETED BY A  
GENERAC AUTHORIZED DEALER  
19  
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Section 5 — Troubleshooting  
Air-cooled 11 kW Generators  
5.1 TROUBLESHOOTING GUIDE  
Problem  
Cause  
Correction  
The engine will not crank.  
1. Fuse blown.  
1. Replace 15A fuse in generator  
control panel.  
2. Loose, corroded or defective  
battery cables.  
2. Tighten, clean or replace  
as necessary.  
3. Defective starter motor.  
4. Dead Battery.  
3. *  
4. Charge or replace battery.  
The engine cranks but  
will not start.  
1. Out of fuel.  
1. Replenish fuel.  
2. *  
3. *  
2. Defective fuel solenoid (FS).  
3. Open #14 wire from  
engine control board.  
4. Defective spark plug(s).  
5. Valve lash out of adjustment.  
4. Clean, re-gap or replace plug(s).  
5. Reset valve lash.  
The engine starts hard  
and runs rough.  
1. Air cleaner plugged  
or damaged.  
1. Check, replace air cleaner.  
2. Defective spark plug(s).  
3. Fuel Pressure incorrect.  
2. Clean, re-gap or replace plug(s).  
3. Confirm fuel pressure to regulator  
is 5-7" water column (0.18 to 0.25)  
for natural gas; 10-12” water col-  
umn (0.36 to 0.43 psi) for liquid  
propane vapor.  
The AUTO/OFF/MANUAL switch  
is set to OFF, but the engine  
continues to run.  
1. Defective switch.  
1. *  
2. *  
2. AUTO/OFF/MANUAL switch  
wired incorrectly.  
3. Defective control board.  
3. *  
There is no AC output from  
the generator.  
1. Main line circuit breaker open. 1. Reset circuit breaker  
to ON (or closed).  
2. Generator internal failure.  
2. *  
There is no transfer to  
standby after utility  
source failure.  
1. Defective transfer switch coil.  
2. Defective transfer relay.  
3. Transfer relay circuit open.  
4. Defective control logic board.  
1. *  
2. *  
3. *  
4. *  
Unit consumes large  
amounts of oil.  
1. Break-in procedure  
1. *  
not followed (see Section 2.1).  
*Contact the nearest Authorized Dealer for assistance.  
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Section 6 — Installation Diagram  
Air-cooled 11 kW Generators  
Installation Diagram – Drawing No. 0E7612-A  
21  
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Section 7 — Electrical Data  
Air-cooled 11 kW Generators  
Wiring Diagram – Drawing No. 0E7071-B  
SCR  
A
B
0
56  
56  
16  
1a  
1
1b  
4
15  
15A  
15B  
SW2  
15  
18  
224  
18  
239  
85  
85  
66A  
0
66A  
0
0
23  
14  
225  
86  
15A  
14  
18  
16  
86  
TB  
4
2
15B  
18  
85  
0
14  
86  
66A  
14  
56  
1
15A  
3
224  
5
239  
7
66A  
9
23  
225  
14  
239  
4
6
8
10 11 12 13 14  
225  
224A  
225A  
J1  
224  
GOVERNOR  
BCR  
14  
15  
15A  
J2  
ACTUATOR  
CONTROL  
PRINTED CIRCUIT BOARD  
1
3
6
9
15A  
10  
5
9
7
6
4
239  
TX  
7
ON  
1
23  
SW1  
66  
A
B
1
2
DSW  
194  
1 - ON=50Hz  
OFF=60Hz  
2 - SPARE  
N1  
N2  
4
224B  
14  
0
225B  
77 86 85 18  
0
15  
15  
194  
L.E.D -  
ALARM INDICATORS  
4
0
6
4
0
6
162  
162  
0
11  
22  
4
11  
22  
4
11  
22  
11  
22  
0
4
6
0
18  
86  
85  
162  
6
0
162  
VOLTAGE  
REGULATOR  
66  
0
66  
77  
0
0
13  
13  
15  
15  
15  
0
0
225B  
0
3
2
F2  
F1  
13  
13  
224B  
13  
13  
13  
N2  
N1  
23  
1
N2  
BATTERY  
CHARGER  
N1  
23  
194  
224B  
15C  
1
2
225B  
DIAGRAM KEY  
BA - BRUSH ASSEMBLY  
BCR - BATTERY CHARGE RELAY  
C1 - 8 POS. DEUTSCH CONNECTOR  
C2 - 12 POS. DEUTSCH CONNECTOR  
CB1 - MAIN OUTPUT BREAKER  
+
-
15C  
0
CB2 - CIRCUIT BREAKER, ALTERNATOR EXCITATION  
CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL  
DIODE  
12VDC ACCESSORY SOCKET  
D
-
DSW - PCB MOUNTED DIP SWITCH  
FS - FUEL SOLENOID  
F1 - FUSE 15 AMP  
F2 - FUSE 7.5 AMP  
GRD 1 - CONTROL PANEL GROUND  
GRD 2 - CONTROL PANEL GROUND, ISOLATED  
HTO - HIGH OIL TEMPERATURE SWITCH  
IC - INLINE CONNECTOR  
IM1, IM2 - IGNITION MODULE, CYLINDER #1/#2  
LOP - LOW OIL PRESSURE SWITCH  
SC - STARTER CONTACTOR  
SCR - STARTER CONTACTOR RELAY  
SM - STARTER MOTOR  
CONTROL PANEL BOX  
SW1 - SWITCH, AUTO / OFF / MANUAL  
SW2 - SWITCH, SET EXERCISE  
SP1, SP2 - SPARK PLUGS  
TB - INSULATED TERMINAL BLOCK  
TX - TRANSFORMER, 16 Vac 56 VA & 16 Vac 1 VA (DUAL SEC.)  
22  
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Section 7 — Electrical Data  
Air-cooled 11 kW Generators  
Wiring Diagram – Drawing No. 0E7071-B  
CLOSEST TO BEARING  
BA  
CB2  
162  
4
0
STATOR  
4
2
2
4
0
4
0
10  
9
6
0
11  
22  
2
6
2
6
2
6
55  
8
7
6
0
66A  
66  
11  
16  
55  
66A  
66  
77  
22  
11  
22  
55  
66A  
66  
77  
11  
22  
55  
66A  
66  
77  
77  
11  
16  
5
4
3
44  
33  
22  
66A  
14  
2
1
C2  
11  
44  
33  
22  
D
162  
14  
0
55  
0
6
4
11 22 14 66 77  
11  
44  
33  
22  
16  
SP2  
FS  
4
0
IM2  
14  
6
IC  
162  
0
0
0
0
8
7
6
5
4
3
2
0
0
D
11  
22  
SP1  
18  
14  
18  
86  
85  
13  
16  
14  
18  
86  
85  
13  
18  
86  
85  
IM1  
86  
66  
77  
1
85  
LOP  
C1  
0
HTO  
0
0
0
0
16  
0
0
0
0
0
55  
0
0
GRD 2  
0
G
GRD 1  
BLACK  
13  
N2  
N1  
23  
RED  
194  
13  
SM  
+
-
12V  
11  
16  
BATTERY  
11  
11  
11  
44  
CB3  
CUSTOMER SUPPLIED  
SC  
33  
22  
N
23  
N1  
194  
N2  
EXTERNAL  
GFCI  
OUTLET  
CB1  
L
ENGINE WIRING  
LOAD  
LINE  
1
3
2
N
L
4
5
240V GENERATOR  
OUTPUT TO TRANSFER  
SWITCH CONTACTOR  
G
G
CUSTOMER  
CONNECTION  
G
23  
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Section 7 — Electrical Data  
Air-cooled 11 kW Generators  
Electrical Schematic – Drawing No. 0E7073-B  
3
2
0
1
BATTERY  
CHARGER  
0
13  
1
224B  
225B  
77  
66  
2
66A  
18  
13  
0
0
0
86  
15  
85  
15  
SCR  
16  
56  
56  
0
224B  
11  
22  
4
16  
0
13  
225B  
77  
66  
18  
66A  
85  
86  
ELECTRONIC  
VOLTAGE  
REGULATOR  
4
4
13  
6
0
6
162  
2
2
16  
14  
CB2  
GOVERNOR  
ACTUATOR  
22  
11  
0
0
11  
22  
MANUAL  
AUTO  
194  
15A  
194  
15A  
12VDC ACCESSORY  
SOCKET  
4
56  
15  
194  
0
194  
15A  
+
-
0
0
0
0
23  
194  
SW1  
15  
239 15C  
239  
225B  
224B  
13  
15  
F2  
F1  
SW2  
15  
15  
15B  
23  
14  
77  
66  
18  
66A  
85  
0
86  
J2  
56  
1
J1  
2
4
3
4
5
6
7
8
9
15A  
18  
77  
15B  
66  
224  
224  
18  
224  
CONTROL  
PRINTED CIRCUIT  
BOARD  
239  
14  
14  
85  
66A  
0
10  
23  
11  
12  
13  
14  
14  
225  
225  
86  
86  
24  
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Section 7 — Electrical Data  
Air-cooled 11 kW Generators  
Electrical Schematic – Drawing No. 0E7073-B  
77  
66  
77  
66  
55  
66A  
66A  
BATTERY  
CHARGE  
WINDING  
77  
ENGINE  
RUN  
WINDING  
66  
66  
ENGINE AND  
ALTERNATOR  
66A  
55  
66A  
77  
IM2  
IM1  
55  
SP2  
SP1  
D
D
77  
66  
BA  
18  
6
2
66A  
18  
FIELD  
18  
DPE  
WINDING  
4
0
STATOR  
86  
85  
POWER  
WINDING  
LOP  
HTO  
6
2
11  
44  
22  
33  
55  
0
0
6
2
4
4
0
13  
RED  
13  
6
SC  
BATTERY  
12V  
2
16  
14  
16  
FS  
SC  
SM  
0
0
0
0
0
0
0
0
0
0
0
11  
22  
11  
22  
11  
22  
33  
44  
22 33  
11 44  
0
23  
G
G
194  
CB3  
225B  
224B  
11  
L
0
N
7
7
9
6
9
BCR  
N
L
1
3
4
G
11 44  
77  
225A  
66  
22 33  
N
CB1  
194 23  
N2 N1  
224A  
14  
77  
66  
NEUTRAL  
G
224  
224A  
240VAC GENERATOR  
OUTPUT TO  
12Vdc  
TRANSFER  
RELAY  
240VAC  
UTILITY  
INPUT  
EXTERNAL  
GFCI  
OUTLET  
225A  
225A  
TRANSFER SWITCH  
CONTACTOR  
14  
COIL  
DIAGRAM KEY  
BA - BRUSH ASSEMBLY  
BCR - BATTERY CHARGE RELAY  
CB1 - CIRCUIT BREAKER, MAIN OUTPUT  
CB2 - CIRCUIT BREAKER, ALT. EXCITATION  
LOP - LOW OIL PRESSURE SWITCH  
SC - STARTER CONTACTER  
SCR - STARTER CONTACTOR RELAY  
SP1, SP2 - SPARK PLUGS  
TX  
N2  
56VA  
1VA  
CB3 - CIRCUIT BREAKER, EXTERNAL OUTLET, PUSH/PULL  
- DIODE  
FS - FUEL SOLENOID  
SW1 - SWITCH, AUTO / OFF / MANUAL  
DPDT, ON-OFF-ON  
224A  
225  
D
225  
SW2 - SWITCH, SET EXERCISE  
SPST, N.C., ON-(OFF)  
SM - STARTER MOTOR  
F1 - FUSE 15 AMP  
F2 - FUSE 5 AMP  
224  
N1  
HTO - HIGH OIL TEMPERATURE SWITCH  
IM1 - IGNITION MODULE, CYLINDER #1  
IM2 - IGNITION MODULE, CYLINDER #2  
TX - TRANSFORMER, 16 Vac 56 VA &  
16 Vac 1 VA (DUAL SEC.)  
25  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 11 kW Generators  
Enclosure – Drawing No. 0E4884-B  
63  
68  
60  
64  
66  
6
1
64  
43  
17  
42  
65  
62  
5
6
50  
52  
74  
17  
40  
8
51  
41  
"A"  
17  
44  
73  
7
16  
86  
85  
8
9
84  
34  
47  
55  
83  
46  
27  
87  
48  
60  
35  
8
37  
17  
11  
54  
24  
33  
33  
8
23  
53  
79  
67  
58  
75  
17  
77  
76  
4
30  
31  
32  
3
6  
6
9  
17  
57  
38  
27  
15  
29  
26  
37  
72  
"A"  
70  
28  
25  
23  
14  
21  
60  
22  
3
17  
18  
15  
20  
26  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 11 kW Generators  
Enclosure – Drawing No. 0E4884-B  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
1
4
0E7325  
0E6884  
0E4706A  
0D1131  
0E4706  
0C2824  
039253  
0A8250  
0C3032  
0C3031  
0E4683  
0E4378  
0E6342  
0E7570  
0E2874  
0E4808  
083512  
0E4809A  
0E4377  
0C2937  
022129  
0E1330A  
4
1
HHFS, 1/4"-20 X 5/8" GRADE 5  
SEAL, ALTERNATOR SHAFT  
SOUND BAFFLE INTAKE SCROLL  
GUARD,FAN  
46  
47  
48  
49  
0E5297A  
0E5297D  
0E5297B  
0E5297C  
1
1
1
1
FOAM, BACK PANEL THERMAL  
ACOUSTIC  
5
1
FOAM, FRONT PANEL THERMAL  
ACOUSTIC  
6
1
7
1
SCROLL, INTAKE  
FOAM, FRONT PANEL THERMAL  
ACOUSTIC  
8
11  
6
SCREW TAP-R #10-32 X 9/16"  
SCREW HHC M8-1.25 X 20  
SCREW HHC 3/8"-24 X 2" G8  
PLATE, FAN  
9
FOAM, BACK PANEL THERMAL  
ACOUSTIC  
DUCT, EXHAUST  
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
1
1
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
79  
80  
81  
82  
83  
84  
85  
86  
87  
0E4385  
0D3037A  
0C7781A  
0E5298C  
0E5298D  
0E4813  
0E4384  
0E4783  
0E6005  
042907  
022145  
040976  
0E5267  
0E3156  
0D5823  
025145  
0E3206  
0E7550  
0E5268  
0D9166  
0E5968  
0E6820  
087233  
0E5298A  
0E5298B  
0E5298G  
0E2833D  
0D7176  
045771  
0A1658  
022237  
022131  
031791  
025034  
0E5298H  
0E5298J  
0E5298K  
1
1
1
FAN FLYWHEEL NYLON  
FAN HUB WITH D-DRIVE  
LATCH, 1/4 TURN NONLOCKING  
PAWL, DOOR  
1
1
1
ASSEMBLY, AIR INTAKE DUCT  
LATCH, ADJUSTABLE DRAW  
GAS SPRING  
1
FOAM, 646 X 447 THERMAL ACOUSTIC  
FOAM, 610 X 452 THERMAL ACOUSTIC  
BAFFLE FRONT EXHAUST DIVIDER  
BAFFLE BACK EXHAUST DIVIDER  
DEFLECTOR, EXHAUST  
1
1
2
1
37  
1
SCREW TAP-R 1/4"-20 X 3/4"  
SUPPORT LOWER AIR INTAKE SEAL  
SCREW HHTT M8-1.2 X 16mm  
BASE PAD  
1
1
4
1
DEFLECTOR, ALTERNATOR AIR  
SCREW HHC M8-1.25 X 16mm  
WASHER FLAT 5/16"-M8  
1
2
1
BASE, ENCLOSURE  
BRACKET BATTERY HOLD DOWN  
WASHER LOCK M8-5/16"  
7
1
4
SCREW SHC M8-1.25 X 20mm  
MUFFLER  
BRACKET, MUFFLER  
12  
1
1
GROMMET, 38.1mm CROSS SLIT WITH  
HOLE  
1
2
BOLT U 5/16"-18 X 1.62" WITH SADDLE  
BOLT U 5/16"-18 X 1.25" WITH SADDLE  
TUBE, MUFFLER INLET  
25  
26  
27  
28  
29  
0E4805  
0E4811  
0D3700  
0E5299D  
0E5299C  
1
1
BRACKET, BATTERY POSITION  
BRACKET, REGULATOR  
1
1
26  
1
NUT FLANGE M6-1.0 NYLOK  
FOAM, ENGINE SIDE PANEL ACOUSTIC  
FOAM, ALTERNATOR SIDE PANEL  
ACOUSTIC  
1
DEFLECTOR, EXHAUST  
1
TAILPIPE, SS HSB EXHAUST  
ASSEMBLY, TWIN REGULATOR  
GASKET, EXTRUDED TRIM  
GASKET, SCROLL  
1
1
9.3'  
1
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
0E5297  
0E4379  
0E5273  
0F0165  
0F0165A  
0F0164A  
036261  
0E7571  
027028  
0E7725  
0E6513  
0E5298F  
0E5298E  
0E4380  
0E4382  
0E5298  
1
1
1
2
1
1
6
2
2
1
1
1
1
1
1
1
FOAM, ENGINE ENCLOUSURE BACK  
ENCLOSURE, POWER HEAD  
RAIL, ROOF STAY SUPPORT  
HINGE TYPE B WITH STUDS, PIN  
HINGE TYPE B WITH STUDS, SOCKET  
HINGE TYPE A WITH STUDS, SOCKET  
RIVET POP 0.125" X 0.275"  
BALL STUD, GAS SPRING MOUNT  
NUT LOCK HEX 5/16-18 NYL INSRT  
BRACKET, GAS SPRING  
5
RIVET POP 0.187" X 0.450"  
FOAM, 746 X 92.5 THERMAL ACOUSTIC  
FOAM, 746 X 42.5 THERMAL ACOUSTIC  
FOAM, 646 X 86.8 THERMAL ACOUSTIC  
SHEET, HARDWRE CLOTH 787 X 267  
WASHER SELF LOCKING  
1
1
1
1
14  
2
NUT HEX M8-1.25 G8  
1
WASHER LOCK SPECIAL 1/4"  
WASHER LOCK 3/8"  
WASHER FLAT 3/8"  
1
ASSEMBLY, ROOF  
1
FOAM, 400 X 220 THERMAL ACOUSTIC  
FOAM, 421.5 X 220 THERMAL ACOUSTIC  
COVER, BACK EXHAUST ENCLOSURE  
COVER, FRONT EXHAUST ENCLOSURE  
FOAM, 746 X 296.5 THERMAL ACOUSTIC  
2
CLAMP CABLE 0.48" X 0.204" PLASTIC  
PLUG STEEL 1.06"  
1
1
FOAM, 110 X 452 THERMAL ACOUSTIC  
FOAM, 146 X 447 THERMAL ACOUSTIC  
FOAM, 146 X 86.8 THERMAL ACOUSTIC  
1
1
27  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 11 kW Generators  
Control Panel – Drawing No. 0E4879-D  
16  
16  
20  
56  
11,12  
63  
15  
18  
19  
2
9
11,13  
17  
16  
10  
9
20  
64  
7
8
8
21  
7
3
8
59  
22  
24  
29  
58  
4
30  
51  
7
8
3
6
52  
31  
32  
33  
54  
48  
22  
47  
48  
47  
24  
25  
25  
4
26  
32  
31  
25  
43  
40  
57  
62  
65  
60  
5
61  
3
2  
3
36  
39  
33  
32  
39  
50  
50  
28  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 11 kW Generators  
Control Panel – Drawing No. 0E4879-D  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
1
0E3312  
1
ASSEMBLY, HOME STANDBY  
CONTROLLER  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
57  
58  
59  
0D8502  
045770  
075475  
049721  
038750  
049813  
054502  
075210A  
0C1085  
0C3910  
043180  
0C2174  
031879  
043182  
051714  
063617  
036903  
0A1658  
059636  
0E5280  
0E6553  
0E6553A  
0912970063  
082625  
0E4381  
0E5840  
1
2
4
1
1
4
1
1
4
1
2
1
4
4
4
1
6
2
4
1
1
1
1
4
1
1
NEUTRAL ISOLATOR  
SCREW HHC M5-0.8 X 10mm  
SCREW PPHM M4-0.7 X 10mm  
SCREW HHC M6-1.0 X 35mm  
SCREW HHC M6-1.0 X 30mm  
NUT HEX M6 X 1.0  
2
3
0A1801  
083049  
092036  
0D3062A  
075235  
049226  
051716  
023484D  
0E4387  
032300  
022676  
0A9611  
0E3928  
0E4494  
074908  
0E4806  
0E5206  
0E6045  
045756  
0E6044  
096021  
046689  
051715  
022264  
075476  
0E7886D  
023897  
0E7890  
1
1
8
4
4
6
6
2
1
2
1
1
1
1
13  
1
1
1
7
1
2
1
8
8
4
1
2
1
ASSEMBLY, BATTERY CHARGER ENGINE  
ASSEMBLY, POTTED REGULATOR  
PPHM S/LW #6-32 X 1/4" LONG  
HEX STAND-OFF #6-32 X 3/4"  
SCREW HHC M5-0.8 X 30mm  
WASHER LOCK M5  
4
5
6
CIRCUIT BREAKER 3 X 1  
BLOCK 1 POSITION  
7
8
NUT HEX M5-0.8  
SNAP BUSHING 0.875"  
SCREW PPHM M3-0.5 X 8mm  
TRANSFORMER  
WASHER FLAT M4  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
CONTROL, PANEL  
HOLDER FUSE  
RELAY 12V 25A SPST  
WASHER FLAT #4  
FUSE, 15AMP X AGC15  
FUSE, 7.5AMP X AGC7.5  
SWITCH, ROCKER SPST (ON)-OFF N/C  
SWITCH ROC DPDT ON-OFF-ON  
SCREW HHTT M5-0.8 X 10mm  
COVER, CONTROL PANEL RIGHT  
COVER, CONTROL PANEL LEFT  
COVER, CONNECTION BOX  
SCREW HHTT M6-1.0 X 10mm  
CONNECTION BOX  
WASHER LOCK M3  
NUT HEX M3-0.5  
RELAY PANEL 12VDC DPDT 10A 240VAC  
SCREW PPHM #6-32 X 5/8"  
WASHER LOCK SPECIAL 1/4"  
PLASTITE PH #4 X 0.37"  
BRACKET, PCB HEADER SUPPORT  
ISOLATOR/SHOULDER WASHER NYLON  
WASHER NYLON 0.50" X 0.32" X 0.12"  
GROUND WIRE  
GROMMET 0.75" X 0.06" X 0.50"  
TERMINAL STRIP  
NUT HEX M4-0.7  
NUT LOCK HEX #6-32 NYL INSERT  
PANEL, TOP COMPARTMENT  
CIRCUIT BREAKER 15A PUSH / PULL  
MAIN RESET  
WASHER LOCK #8-M4  
SCREW PPHM M4-0.7 X 16mm  
CIRCUIT BREAKER  
WASHER FLAT #10  
60  
61  
62  
63  
64  
65  
66  
0E4261  
0E7833  
022985  
1
1
4
1
1
1
4
OUTLET, 15A GFCI DUPLEX  
PLATE, WEATHERPROOF GFCI  
WASHER FLAT #6  
CIRCUIT BREAKER MOUNTING  
BRACKET  
0E9056  
0912970064  
0E9171  
043182  
SOCKET, 12VDC ACCESSORY  
GROUND WIRE  
30  
31  
32  
33  
083512  
022507  
022097  
022473  
1
2
SCREW HHTT M8-1.2 X 16mm  
SCREW HHC 1/4"-20 X 1/2" LONG  
WASHER LOCK M6-1/4"  
WASHER FLAT 1/4"-M6  
GASKET, WEATHERPROOF GFCI  
WASHER LOCK M3  
4
10  
29  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 11 kW Generators  
GT-990 Engine – Drawing No. 0F2000  
4
5
2
6
54  
55  
56  
7
8
19  
9
10  
51  
53  
52  
50  
11  
15  
49  
14  
12  
13  
47  
22  
43  
42  
41  
40  
39  
38  
23  
45  
44  
36  
21  
16  
2
17  
4
18  
25  
37  
35  
3
26  
27  
34  
29  
28  
33  
30  
30  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 11 kW Generators  
GT-990 Engine – Drawing No. 0F2000  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
0C5730A  
0E9843  
090388  
0C5372  
0C3005  
0E3372A  
0D8067A  
0C2981C  
071983  
0E2950  
021533  
0E1466  
0D4041  
0C2977  
0C5943  
0E4357A  
082774  
0E3223  
0C2978  
093873  
021374  
0C2994  
0C2997  
0C2995  
0C2996  
0C3011  
0C3009  
0C3010  
050873A  
0E9842  
0D9756  
0C5732A  
0C3006  
080318  
0C2982  
093064  
0C2979  
086515  
0D2274  
0D3867  
078672  
0C5371  
0D3998  
072694  
0D5313  
0E3273  
0D6024  
0C2976  
0D8067B  
0C2229  
086516  
0D9853D  
083897  
0E9323  
022129  
061906  
1
1
6
1
1
1
1
1
4
2
2
2
1
1
1
1
1
2
2
3
3
1
1
1
1
2
2
2
1
1
1
1
10  
8
1
1
2
8
4
4
2
4
4
4
4
1
2
12  
1
2
2
4
4
1
2
2
ASSEMBLY, CRANKCASE RV  
SEAL, 38 I.D. CRANKCASE  
SCREW, HHTT M6-1.0 X 12mm  
ASSEMBLY, BREATHER  
GASKET, BREATHER COVER  
SEPARATOR, OIL BREATHER  
ASSEMBLY, HEAD #1  
3
4
5
6
7
8
COVER, ROCKER  
RETAINER, PISTON PIN 20  
PISTON  
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
54  
55  
56  
SET, PISTON RING 90mm  
PIN , PISTON  
ASSEMBLY, CAMSHAFT & GEAR  
GASKET, CRANK CASE  
SEAL, OIL PASSAGE  
ASSEMBLY, CRANKSHAFT  
KEY, WOODRUFF 4 X 19D  
ASSEMBLY, CONNECTING ROD  
GASKET, HEAD  
WASHER, LOCK RIB M6  
SCREW, SHC M6-1.0 X 30mm  
SCREEN, OIL PICKUP  
COVER, GEROTOR  
GEROTOR, INNER  
GEROTOR, OUTER  
COVER, OIL RELIEF  
SPRING, OIL RELIEF  
BALL, 1/2D OIL RELIEF  
1/4" NPT PIPE PLUG  
SEAL, 42 I.D. CRANKSHAFT  
CONNECTOR, 3/8NPT TO INVTD FLR 3/8OD  
ASSEMBLY SUMP WITH PLUG  
SCREW, HHFC M10-1.5 X 55mm  
SCREW HHFC M6-1.0 X 25mm  
COVER, ROCKER WITH OIL FILL  
ASSEMBLY, OIL FILL CAP  
GASKET, VALVE COVER  
KEEPER, VALVE SPRING  
RETAINER, VALVE SPRING  
SPRING, VALVE  
SEAL, VALVE STEM D7  
WASHER, VALVE SPRING  
NUT HEX M8-1.0 G8  
STUD ROCKER ARM PIVOT  
ROCKER ARM  
SCREEN CRANKCASE BREATHER  
PLATE, PUSH ROD GUIDE  
SCREW HHFC M8-1.25 X 65mm  
ASSEMBLY, HEAD #2  
VALVE, INTAKE  
VALVE, EXHAUST  
PUSHROD 147  
TAPPET, SOLID  
STARTER MOTOR  
WASHER LOCK M8  
SCREW, HHC M8-1.25 X 85mm  
31  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 11 kW Generators  
Engine Accessories – Drawing No. 0F2001-D  
1
20  
2
90  
89  
4
88  
3
87  
98  
51  
86  
44  
85  
43  
"A"  
83  
84  
"C"  
"E"  
9
7
8
77  
79  
78  
6
5
10  
94  
TO REGULATOR  
80  
93  
11  
76  
102  
12  
95  
81  
80  
74  
72  
1
16  
75  
13  
1
73  
62  
61  
19  
"A"  
71  
56  
"C"  
14  
69  
70  
60  
66  
59  
63  
64  
45  
68  
67  
15  
"B"  
17  
65  
58  
44  
55  
54  
44  
18  
100  
43  
44  
50  
19  
97  
99  
51  
57  
21  
22  
91  
"E"  
1
49  
1
53  
52  
82  
41  
19  
101  
44  
42  
38  
101  
44  
40  
19  
37  
92  
19  
23  
50  
32  
31  
39  
35  
"B" 48  
36  
34  
47  
46  
28  
27  
30  
24  
33  
29  
26  
25  
32  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 11 kW Generators  
Engine Accessories – Drawing No. 0F2001-D  
ITEM PART NO. QTY. DESCRIPTION  
ITEM PART NO. QTY. DESCRIPTION  
1
2
045756  
0D1131  
0F1169G  
0C9763  
0E4386  
0E5079  
0C3034  
0C3033  
051754  
0A5992  
0C3032  
0C3031  
0C3725A  
0F1170A  
023484S  
0D9679A  
0E6481  
11  
1
1
4
1
1
1
1
2
2
1
1
1
1
1
1
1
SCREW HHTT M6-1.0 X 10 YC  
GUARD, FAN  
53  
54  
0D9680A  
0D1143A  
1
1
WRAPPER, VALLEY SPCC  
WRAPPER,UPPER #2 WITH M8 WELD  
NUT  
3
HOUSING, BLOWER V-TWIN RV  
NUT,GROMMET 1/4 PLUG  
TUBE, INTAKE  
4
55  
56  
57  
58  
59  
60  
61  
62  
63  
64  
65  
66  
67  
68  
69  
70  
71  
72  
73  
74  
75  
76  
77  
78  
79  
80  
81  
82  
83  
84  
85  
86  
87  
88  
89  
90  
91  
92  
93  
94  
95  
96  
97  
98  
99  
100  
101  
102  
0E7209  
0E4997  
0D9852  
092079  
0A7215  
078643B  
0E4867  
0E5293  
082774  
0C1547  
0C1546  
0A5358  
0D9312  
0D9314  
0C1557  
0A9028  
0D9682A  
0E0573  
0E1217A  
0E0572  
0C3043  
0D8836  
049821  
070008  
070006  
048031M  
0F7065  
0E6885  
0D1366  
035461  
0F6301  
0C9806  
0C3026  
0D9683A  
0D6029  
0C9764  
0C3024  
0E6314  
0E3077  
0388050AH0  
0388040AM0  
0E7351  
0C3040  
055934D  
0C5136A  
0C8127  
049811  
075763A  
1
1
2
4
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
4
4
4
2
18”  
1
1
2
4
2
1
1
2
4
1
1
1
1
1
1
1
1
2
1
2
1
ASSEMBLY GROUNDING WIRE  
ASSEMBLY GROUND WIRE CONNECTOR  
ASSEMBLY IGNITION COIL  
SCREW HHTT M6-1.0 X 25mm BP  
SCREW SW 1/4”-20 X 5/8” WITH WASHER  
BOLT,CARB MOUNT M6-1.0 x85mm  
BASE, AIR CLEANER  
5
6
HOSE, BREATHER  
7
NUT HEX M24-2.0 G8 YEL CHR  
WASHER,BELLEVILLE 25MM BOLT  
SCREW HHC M8-1.25 X 12 G8.8  
WASHER SHAKEPROOF INT M8 SS  
PLATE, FAN  
8
9
10  
11  
12  
13  
14  
15  
16  
17  
BOOT, INTAKE  
FAN NYLON  
FLYWHEEL ASSEMBLY  
KEY, WOODRFF 4 X 19D  
O-RING 21.89 X 27.13 X 2.62mm  
O-RING 59.92 X 66.98 X 3.53mm  
ADPTR OIL PAD, FLARE  
TUBE, ENGINE OIL RETURN  
TUBE, ENGINE OIL OUT  
O-RING 20.35 X 23.91 X 1.78mm  
BOLT, OIL ADAPTOR  
PLATE,BACKING WITH OIL COOL  
BUSHING SNAP  
WRAP, CRANKCASE SPCC  
GT990 VERTICAL SHAFT DUEL/FUEL  
ENGINE  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
0F1167A  
056893  
055934M  
074908  
0E7585  
0E0998  
0E4871  
043790  
0D3083  
0E0361A  
0E0393  
0C2824  
065852  
075246  
0A4456  
0A2311  
070185B  
0A8584  
0A5360  
043182  
0C1085  
0E1497  
0E3305  
0E5072  
0E5108  
047487  
022097  
0E4988  
055173  
022129  
022145  
0D9801A  
047411  
022473  
0C3018A  
1
13  
1
2
2
1
1
1
1
1
1
1
1
4
1
2
1
1
1
2
2
1
1
1
1
2
12  
1
2
2
2
1
4
4
1
WRAP, CYLINDER 1 SPCC  
SCREW CRIMPTITE #10-24 X 1/2”  
CLAMP VINYL  
WRAPPER, CYLINDER #2 SPCC  
GASKET,CARB TO ADAPTOR  
CARBURETOR  
SCREW HHTT M5-0.8 X 10mm BP  
SPARK PLUG  
GASKET,CARB TO INTAKE MANIFOLD  
GASKET INTAKE PORT  
MANIFOLD, INTAKE  
CLAMP VINYL 9.5 O.D. TUBE  
TUBE, OIL PASSAGE  
BARBED ELBOW 90 3/8NPT X 3/8  
ASSEMBLY, OIL DRAIN HOSE  
OIL DRAIN / DIPSTICK TUBE  
ASSEMBLY, CAP & DIP STICK  
SCREW TAP-R #10-32 X 9/16”  
SPRING CLIP HOLDER 0.37”-0.62”  
SCREW HHTT 3/8”-16 X 1-1/4”  
WASHER LOCK SPECIAL 3/8  
SCREW SWAGE 1/4”-20 X 1”  
OIL FILTER  
SCREW SHC M8-1.25 X 30mm G12.9  
WASHER FLAT M8 SS  
WASHER LOCK M8 SS  
CLAMP HOSE  
HOSE 1\2” I.D.  
SPRING, ANTI-LASH  
BUSHING, GOVERNOR ROD  
BARBED STRAIT 1/4”NPT X 3/8”  
CLAMP, HOSE OETIKER 16.5mm  
HOSE,3/8” I.D. x 6”  
SWITCH OIL PRESSURE  
SUPPORT OIL FLTR FLARE  
WASHER LOCK M3  
COOLER, OIL  
DUCT, OIL COOLER SPCC  
SCREW HHTT M6-1.0 X 16mm  
PLASTITE, 1/4”-15 X 3/4”  
COVER, AIRBOX  
SCREW PPHM M3-0.5 X 8mm  
SWITCH, OIL HIGH TEMPERATURE  
BRACKET, STEPPER MOTOR MOUNT  
ROD, GOVERNOR  
PLUG PANEL PLASTIC 0.562”  
SLEEVE 5/8” I.D. X 12.5” LONG  
CABLE BATTERY BLACK #6 48”  
CABLE BATTERY RED #6 48”  
ENGINE HARNESS (NOT SHOWN)  
PRE-CLEANER  
CONTROLLER  
SCREW SHC M6-1.0 X 18mm  
WASHER LOCK M6-1/4”  
AIR BOX SUPPORT BRACKET  
SCREW HHC M8-1.25 X 20mm G10.9  
WASHER LOCK M8-5/16”  
WASHER FLAT 5/16”-M8 ZINC  
WRAP, VALLEY UPPER SPCC  
SCREW HHC M6-1.0 X 16mm  
WASHER FLAT M6  
CLAMP VINYL 1.06” X 0.406” Z  
KNOB, AIR CLEANER  
ELEMENT, AIR CLEANER  
WASHER FLAT M6  
BOOT, BATTERY CABLE  
WRAPPER, UPPER #1 WITH M8 WELD  
NUT  
33  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 11 kW Generators  
Alternator & Pulleys – Drawing No. 0E4880  
34  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 11 kW Generators  
Alternator & Pulleys – Drawing No. 0E4880  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
0E0196A  
022129  
022145  
022259  
0C7758  
0C3168  
0C2417  
0E2424A  
0E2425  
0E2421  
0E1078A  
0E3020  
040976  
056893  
023897  
0E1078  
0C4138  
043116  
022097  
022473  
0C1752  
0C1753B  
075224D  
073118  
0E5984  
022131  
0C2824  
0A9827B  
042633  
022237  
049451  
0C1441  
0C1112  
083512  
039288  
029459  
075215  
052858  
075237  
075242  
0A9202  
0A9918  
0E0575  
0A9226  
0E4748  
031971  
0E3233  
073159  
0E3229  
0A9227  
066386  
066849  
056326  
1
7
FRAME, MOUNTING SS HSB  
WASHER LOCK M8-5/16  
WASHER FLAT 5/16-M8 ZINC  
NUT HEX 5/16-18 STEEL  
VIB MNT 1.5 X 1.38 X 5/16-18  
WASHER LOCK SPECIAL 5/16  
EARTH STRAP  
3
8
4
4
5
4
6
1
7
1
8
1
SKID, MOUNT ALTERNATOR  
SKID, MOUNT ENGINE  
MANIFOLD, EXHAUST  
9
1
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
31  
32  
33  
34  
35  
36  
37  
38  
39  
40  
41  
42  
43  
44  
45  
46  
47  
48  
49  
50  
51  
52  
53  
1
1
GASKET, EXHAUST BASE  
BRACKET, FRAME EXTENSION  
SCREW SHC M8-1.25 X 20mm  
SCREW CRIMPTITE 10-24 X ½  
WASHER FLAT #10 ZINC  
GASKET, EXHAUST BASE  
GASKET,EXHAUST PORT  
SCREW HHC M6-1.0 X 12 G8.8  
WASHER LOCK M6-1/4  
WASHER FLAT 1/4-M6 ZINC  
FAN NYLON 8" DIA  
1
4
6
5
1
2
3
3
3
1
1
PULLEY, ALTERNATOR 2200 RPM  
PULLEY ENGINE 3600 RPM  
SCREW HHC 3/8"-24 X 2-1/4"  
DUCT, ALTERNATOR COVER  
WASHER FLAT 3/8-M10 ZINC  
SCREW TAP-R #10-32 X 9/16"  
BLOWER HOUSING  
1
1
1
1
6
1
1
SCREW HHC 3/8"-24 X 1"  
WASHER LOCK 3/8"  
2
1
WASHER FLAT 0.406" I.D. X 1.62" O.D.  
SET,BLOWER HOUSING GASKET  
BELT,V-RIB 4LX42.75"  
1
1
4
SCREW HHTT M8-1.2 X 16mm  
SCREW HHC M8-1.25 X 55mm  
TENSION SPRING  
2
2
2
WASHER, SPRING CENTER  
NUT LOCK FLANGE M8-1.25  
WASHER, SPRING CENTER  
SPRING, MOUNT  
10  
4
4
2
SUPPORT, SLIDE  
SLIDE, NYLON  
4
3.5 FT  
1
FOAM SEALING STRIP 1"  
BEARING CARRIER LOWER  
STUD, STATOR  
4
1
BEARING  
ROTOR  
1
1
BEARING  
STATOR  
1
1
BEARING CARRIER UPPER  
ASSEMBLY, BRUSH HOLDER  
SCREW HHTT M5-0.8 x 16mm  
TRIM VINYL BLACK  
1
2
3.4'  
35  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 11 kW Generators  
Regulator – Drawing No. 0E4881-C  
36  
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Section 8 — Exploded Views and Parts Lists  
Air-cooled 11 kW Generators  
Regulator – Drawing No. 0E4881-C  
ITEM  
PART NO.  
QTY.  
DESCRIPTION  
1
2
0D5694  
0F5022  
0C4647  
0C4680  
0C6070  
0F4795  
0D3973  
0E6183  
0E6184  
0D3308  
0C5761  
0C5968  
0C6066  
0C5759  
0C5764  
070728  
0C6069  
0C5762  
045764  
0C6731  
0C6067  
0C4706  
0C6068  
0C4643A  
026073  
0E1010A  
0C5760G  
0C6606  
1
1
1
1
1
4
2
2
1
4
2
2
2
2
2
4
2
2
16  
2
2
2
2
2
2
1
1
1
CASTING, TWIN REGULATOR HOUSING  
SOLENOID COIL, 12VDC  
GASKET , SOLENOID  
3
4
PLUNGER, LP REGULATOR ASSEMBLY  
SPRING-SOLENOID, PLUNGER  
SCREW PPHM SEMS M4-0.7 X 10  
PLUG, EXPANSION 16mm  
ELBOW 90D STREET 1/2”  
PLUG PIPE 1/2” COUNTERSUNK  
WASHER, FLAT M3 X 10mm O.D.  
LEVER, REGULATOR  
5
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
29  
30  
SUPPORT, INLET SEAL  
SEAL, INLET  
PIN, PIVOT ARM  
SPRING, REGULATOR  
SCREW, PFHMS M3-0.5 x 5  
GASKET, DIAPHRAGM  
COVER, TWIN REGULATOR  
SCREW, TAPTITE M4X8 BP  
RIVET, POP .118 X .125  
SUPPORT, DIAPHRAGM  
DIAPHRAGM, TWIN REGULATOR  
CAP, DIAPHRAGM SUPPORT  
INLET, TWIN REGULATOR 11.11 DIA.  
PLUG, STANDARD PIPE 1/8 STEEL SQUARE HEAD  
JET, GT990 LP GAS  
JET, GT990 NAT GAS  
BARBED STR 1/2 X 1/2NPT  
37  
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Section 9 — Notes  
Air-cooled 11 kW Generators  
38  
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Section 9 — Notes  
Air-cooled 11 kW Generators  
39  
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Section 10 – Warranty  
Air-cooled 11 kW Generators  
NOTE: This Emission Control Warranty Statement pertains to this product only IF the generator size is 15 kW or below.  
CALIFORNIA EMISSION CONTROL WARRANTY STATEMENT  
YOUR WARRANTY RIGHTS AND OBLIGATIONS  
The California Air Resources Board (CARB) and Generac Power Systems, Inc. (Generac) are pleased to explain the Emission  
Control System Warranty on your new engine.* In California, new utility, and lawn and garden equipment engines must be  
designed, built and equipped to meet the state’s stringent anti-smog standards. Generac will warrant the emission control  
system on your engine for the periods of time listed below provided there has been no abuse, neglect, unapproved modifica-  
tion or improper maintenance of your engine.  
Your emission control system may include parts such as the carburetor, ignition system and exhaust system. Generac will  
repair your engine at no cost to you for diagnosis, replacement parts and labor, should a warrantable condition occur.  
MANUFACTURER’S EMISSION CONTROL SYSTEM WARRANTY COVERAGE:  
Emissions control systems on 1995 and later model year engines are warranted for two years as hereinafter noted. If, dur-  
ing such warranty period, any emission-related component or system on your engine is found to be defective in materials or  
workmanship, repairs or replacement will be performed by a Generac Authorized Warranty Service Facility.  
PURCHASER’S/OWNER’S WARRANTY RESPONSIBILITIES:  
As the engine purchaser/owner, you are responsible for the completion of all required maintenance as listed in your factory  
supplied Owner’s Manual. For warranty purposes, Generac recommends that you retain all receipts covering maintenance  
on your engine. However, Generac cannot deny warranty solely due to the lack of receipts or for your failure to ensure the  
completion of all scheduled maintenance.  
As the engine purchaser/owner, you should, however, be aware that Generac may deny any and/or all warranty coverage or  
responsibility if your engine, or a part/component thereof, has failed due to abuse, neglect , improper maintenance or unap-  
proved modifications, or the use of counterfeit and/or “grey market” parts not made, supplied or approved by Generac.  
You are responsible for contacting a Generac Authorized Warranty Service Facility as soon as a problem occurs. The  
warranty repairs should be completed in a reasonable amount of time, not to exceed 30 days.  
Warranty service can be arranged by contacting either your selling dealer or a Generac Authorized Warranty Service Facility.  
To locate the Generac Authorized Warranty Service Facility nearest you, call our toll-free number:  
1-800-333-1322  
IMPORTANT NOTE: This warranty statement explains your rights and obligations under the Emission Control System  
Warranty (ECS Warranty), which is provided to you by Generac pursuant to California law. See also the “Generac Limited  
Warranties for Generac Power Systems, Inc.,” which is enclosed herewith on a separate sheet, also provided to you by  
Generac. The ECS Warranty applies only to the emission control system of your new engine. If there is any conflict in  
terms between the ECS Warranty and the Generac Warranty, the ECS Warranty shall apply except in circumstances where  
the Generac Warranty may provide a longer warranty period. Both the ECS Warranty and the Generac Warranty describe  
important rights and obligations with respect to your new engine.  
Warranty service can be performed only by a Generac Authorized Warranty Service Facility. When requesting warranty ser-  
vice, evidence must be presented showing the date of the sale to the original purchaser/owner.  
If you have any questions regarding your warranty rights and responsibilities, you should contact Generac at one of  
the following addresses:  
For Air-cooled Product ...  
For Liquid-cooled Product ...  
ATTENTION WARRANTY DEPARTMENT  
GENERAC POWER SYSTEMS, INC.  
P.O. BOX 297  
WHITEWATER, WI 53190  
Part 1  
ATTENTION WARRANTY DEPARTMENT  
GENERAC POWER SYSTEMS, INC.  
211 MURPHY DRIVE  
EAGLE, WI 53119  
40  
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Section 10 – Warranty  
Air-cooled 11 kW Generators  
EMISSION CONTROL SYSTEM WARRANTY  
Emission Control System Warranty (ECS Warranty) for 1995 and later model year engines:  
(a) Applicability: This warranty shall apply to 1995 and later model year engines. The ECS Warranty Period shall begin on the  
date the new engine or equipment is purchased by/delivered to its original, end-use purchaser/owner and shall continue  
for 24 consecutive months thereafter.  
(b) General Emissions Warranty Coverage: Generac warrants to the original, end-use purchaser/owner of the new engine or  
equipment and to each subsequent purchaser/owner that each of its engines is ...  
(1) Designed, built and equipped so as to conform with all applicable regulations adopted by the CARB pursuant to its  
authority, and  
(2) Free from defects in materials and workmanship which, at any time during the ECS Warranty Period, may cause a  
warranted emissions-related part to fail to be identical in all material respects to the part as described in the engine  
manufacturer’s application for certification.  
(c) The ECS Warranty only pertains to emissions-related parts on your engine, as follows:  
(1) Any warranted, emissions-related parts that are not scheduled for replacement as required maintenance in the Owner’s  
Manual shall be warranted for the ECS Warranty Period. If any such part fails during the ECS Warranty Period, it shall  
be repaired or replaced by Generac according to Subsection (4) below. Any such part repaired or replaced under the  
ECS Warranty shall be warranted for the remainder of the ECS Warranty Period.  
(2) Any warranted, emissions-related part that is scheduled only for regular inspection as specified in the Owner’s Manual  
shall be warranted for the ECS Warranty Period. A statement in such written instructions to the effect of “repair or  
replace as necessary” shall not reduce the ECS Warranty Period. Any such part repaired or replaced under the ECS  
Warranty shall be warranted for the remainder of the ECS Warranty Period.  
(3) Any warranted, emissions-related part that is scheduled for replacement as required maintenance in the Owner’s  
Manual shall be warranted for the period of time prior to the first scheduled replacement point for that part. If the part  
fails prior to the first scheduled replacement, the part shall be repaired or replaced by Generac according to Subsection  
(4) below. Any such emissions-related part repaired or replaced under the ECS Warranty shall be warranted for the  
remainder of the ECS Warranty Period prior to the first scheduled replacement point for such emissions-related part.  
(4) Repair or replacement of any warranted, emissions-related part under this ECS Warranty shall be performed at no  
charge to the owner at a Generac Authorized Warranty Service Facility.  
(5) When the engine is inspected by a Generac Authorized Warranty Service Facility, the owner shall not be held responsible  
for diagnostic costs if the repair is deemed warrantable.  
(6) Generac shall be liable for damages to other original engine components or approved modifications proximately caused  
by a failure under warranty of any emission-related part covered by the ECS Warranty.  
(7) Throughout the ECS Warranty Period, Generac shall maintain a supply of warranted emission-related parts sufficient  
to meet the expected demand for such emission-related parts.  
(8) Any Generac authorized and approved emission-related replacement part may be used in the performance of any ECS  
Warranty maintenance or repairs and will be provided without charge to the owner. Such use shall not reduce Generac  
ECS Warranty obligations.  
(9) Unapproved, add-on, modified, counterfeit and/or “grey market” parts may not be used to modify or repair a Generac  
engine. Such use voids this ECS Warranty and shall be sufficient grounds for disallowing an ECS Warranty claim.  
Generac shall not be held liable hereunder for failures of any warranted parts of a Generac engine caused by the use of  
such an unapproved, add-on, modified, counterfeit and/or “grey market” part.  
EMISSION RELATED PARTS INCLUDE THE FOLLOWING:  
1) Fuel Metering System:  
3) Ignition System including:  
a) Spark plug  
b) Ignition module  
1.2) LPG/Natural Gas carburetion assembly and its internal  
components.  
a) Fuel controller (if so equipped)  
4) Catalytic Muffler Assembly (if so equipped) including:  
a) Muffler gasket  
b) Exhaust manifold  
b) Mixer and its gaskets (if so equipped)  
c) Carburetor and its gaskets (if so equipped)  
d) Primary gas regulator (if so equipped)  
e) LP liquid vaporizer (if so equipped)  
5) Crankcase Breather Assembly including:  
a) Breather connection tube  
2) Air Induction System including:  
a) Intake pipe/manifold  
b) Air cleaner  
*Generac engine types covered by this warranty statement include the following:  
1) Prepackaged Standby Generator  
2) Auxiliary Power Unit (APU) Generator  
3) Standby Generator  
Part 2  
41  
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Section 10 – Warranty  
Air-cooled 11 kW Generators  
GENERAC POWER SYSTEMS “TWO YEAR” LIMITED WARRANTY FOR QUIETSOURCE™  
“PREPACKAGED EMERGENCY AUTOMATIC STANDBY GENERATORS”  
For a period of two years from the date of original sale, Generac Power Systems, Inc. (Generac) warrants that its Quietsource gen-  
erator will be free from defects in material and workmanship for the items and period set forth below. Generac will, at its option, repair  
or replace any part which, upon examination, inspection and testing by Generac or an Authorized Warranty Service Dealer, is found  
to be defective. Any equipment that the purchaser/owner claims to be defective must be examined by the nearest Authorized Warranty  
Service Dealer. All transportation costs under the warranty, including return to the factory, are to be borne and prepaid by the pur-  
chaser/owner. This warranty applies only to Generac Quietsource prepackaged emergency automatic standby generators sold and  
rated for use in “Standby” applications.  
WARRANTY SCHEDULE  
YEARS ONE and TWO - 100% (one hundred percent) transferable coverage on Labor and Part(s) listed (proof of purchase and main-  
tenance is required):  
Engine - All Components  
Alternator - All Components  
Transfer System - All Components  
All warranty expense allowances are subject to the conditions defined in Generac’s Warranty Policies, Procedures and Flat Rate  
Manual.  
THIS WARRANTY SHALL NOT APPLY TO THE FOLLOWING:  
• Quietsource generators that utilize non-Generac/Quietsouce replacement parts.  
• Quietsource generators utilizing non-Generac/Quietsource automatic transfer switches.  
• Repairs performed by individuals other than Guardian/Generac authorized dealers.  
• Any Quietsource generators used as rental or trailer mounted applications.  
• Air-cooled units used for prime power in place of existing utility power where utility power is present or in place of utility power where  
utility power service does not normally exist.  
• Costs of normal maintenance, adjustments, installation and start-up.  
• Failures caused by any contaminated fuels, oils, coolants or lack of proper fluid amounts.  
• Failures due, but not limited, to normal wear and tear, accident, misuse, abuse, negligence or improper installation. As with all  
mechanical devices, the Generac engines need periodic part(s) service and replacement to perform well. This warranty will not  
cover repair when normal use has exhausted the life of a part(s) or engine.  
• Failures caused by any external cause or act of God, such as collision, theft, vandalism, riot or wars, nuclear holocaust, fire,  
freezing, lightning, earthquake, windstorm, hail, volcanic eruption, water or flood, tornado or hurricane.  
• Damage related to rodent and/or insect infestation.  
• Products that are modified or altered in a manner not authorized by Generac in writing.  
• Any incidental, consequential or indirect damages caused by defects in materials or workmanship, or any delay in repair or  
replacement of the defective part(s).  
• Failure due to misapplication.  
• Telephone, cellular phone, facsimile, internet access or other communication expenses.  
• Living or travel expenses of person(s) performing service, except as specifically included within the terms of a specific unit warranty  
period.  
• Expenses related to “customer instruction” or troubleshooting where no manufacturing defect is found.  
• Rental equipment used while warranty repairs are being performed.  
• Costs incurred for equipment used for removal and/or reinstallation of generator, (i.e.; cranes, hoists, lifts, etc.)  
• Overnight freight costs for replacement part(s).  
• Overtime labor.  
• Starting batteries, fuses, light bulbs and engine fluids.  
THIS WARRANTY IS IN PLACE OF ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED. SPECIFICALLY, GENERAC MAKES  
NO OTHER WARRANTIES AS TO THE MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE. Some states do not  
allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.  
GENERAC’S ONLY LIABILITY SHALL BE THE REPAIR OR REPLACEMENT OF PART(S) AS STATED ABOVE. IN NO EVENT  
SHALL GENERAC BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES, EVEN IF SUCH DAMAGES ARE A  
DIRECT RESULT OF GENERAC’S NEGLIGENCE. Some states do not allow the exclusion or limitation of incidental or consequential  
damages, so the above limitation may not apply to you.  
This warranty gives you specific legal rights. You also have other rights from state to state.  
®
GENERAC POWER SYSTEMS, INC.  
P.O. BOX 297 • WHITEWATER, WI 53190  
Revision (10/01/04)  
Part No. 0E4885  
Revision E (12/06/05)  
Printed in U.S.A.  
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